Search results for: finite element simulation

Authors: A. Vairis, M. Petousis, B. Kandyla, C. Chrisoulakis

Abstract:

The human knee joint has a three dimensional geometry with multiple body articulations that produce complex mechanical responses under loads that occur in everyday life and sports activities. To produce the necessary joint compliance and stability for optimal daily function various menisci and ligaments are present while muscle forces are used to this effect. Therefore, knowledge of the complex mechanical interactions of these load bearing structures is necessary when treatment of relevant diseases is evaluated and assisting devices are designed. Numerical tools such as finite element analysis are suitable for modeling such joints in order to understand their physics. They have been used in the current study to develop an accurate human knee joint and model its mechanical behavior. To evaluate the efficacy of this articulated model, static load cases were used for comparison purposes with previous experimentally verified modeling works drawn from literature.

Keywords: biomechanics, finite element modeling, knee joint

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Authors: Yu Luan

Abstract:

The bone-conducted objective occlusion effect (OE) is characterized by a discomforting sensation of fullness experienced in an occluded ear. This phenomenon arises from various external stimuli, such as human speech, chewing, and walking, which generate vibrations transmitted through the body to the ear canal walls. The bone-conducted OE occurs due to the pressure build-up inside the occluded ear caused by sound radiating into the ear canal cavity from its walls. In the hearing aid industry, artificial ears are utilized as a tool for developing hearing aids. However, the currently available commercial artificial ears primarily focus on pure acoustics measurements, neglecting the bone-conducted vibration aspect. This research endeavors to develop an artificial ear specifically designed for bone-conducted occlusion measurements. Finite Element Analysis (FEA) modeling has been employed to gain insights into the behavior of the artificial ear.

Keywords: Artificial ear, bone conducted vibration, occlusion measurement, Finite Element Modeling.

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Authors: Aymen Laadhari

Abstract:

We present in this paper a fully implicit finite element method tailored for the numerical modeling of inextensible fluidic membranes in a surrounding Newtonian fluid. We consider a highly simplified version of the Canham-Helfrich model for phospholipid membranes, in which the bending force and spontaneous curvature are disregarded. The coupled problem is formulated in a fully Eulerian framework and the membrane motion is tracked using the level set method. The resulting nonlinear problem is solved by a Newton-Raphson strategy, featuring a quadratic convergence behavior. A monolithic solver is implemented, and we report several numerical experiments aimed at model validation and illustrating the accuracy of the proposed method. We show that stability is maintained for significantly larger time steps with respect to an explicit decoupling method.

Keywords: Finite element method, Newton method, level set, Navier-Stokes, inextensible membrane, liquid drop.

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Authors: S. Boria

Abstract:

In the last years, the crashworthiness of an automotive body structure can be improved, since the beginning of the design stage, thanks to the development of specific optimization tools. It is well known how the finite element codes can help the designer to investigate the crashing performance of structures under dynamic impact. Therefore, by coupling nonlinear mathematical programming procedure and statistical techniques with FE simulations, it is possible to optimize the design with reduced number of analytical evaluations. In engineering applications, many optimization methods which are based on statistical techniques and utilize estimated models, called meta-models, are quickly spreading. A meta-model is an approximation of a detailed simulation model based on a dataset of input, identified by the design of experiments (DOE); the number of simulations needed to build it depends on the number of variables. Among the various types of meta-modeling techniques, Kriging method seems to be excellent in accuracy, robustness and efficiency compared to other ones when applied to crashworthiness optimization. Therefore the application of such meta-model was used in this work, in order to improve the structural optimization of a bumper for a racing car in composite material subjected to frontal impact. The specific energy absorption represents the objective function to maximize and the geometrical parameters subjected to some design constraints are the design variables. LS-DYNA codes were interfaced with LS-OPT tool in order to find the optimized solution, through the use of a domain reduction strategy. With the use of the Kriging meta-model the crashworthiness characteristic of the composite bumper was improved.

Keywords: Composite material, crashworthiness, finite element analysis, optimization.

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Authors: Yaoxin Zhang, Yafei Jia, Sam S.Y. Wang

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A multi-block algorithm and its implementation in two-dimensional finite element numerical model CCHE2D are presented. In addition to a conventional Lagrangian Interpolation Method (LIM), a novel interpolation method, called Consistent Interpolation Method (CIM), is proposed for more accurate information transfer across the interfaces. The consistent interpolation solves the governing equations over the auxiliary elements constructed around the interpolation nodes using the same numerical scheme used for the internal computational nodes. With the CIM, the momentum conservation can be maintained as well as the mass conservation. An imbalance correction scheme is used to enforce the conservation laws (mass and momentum) across the interfaces. Comparisons of the LIM and the CIM are made using several flow simulation examples. It is shown that the proposed CIM is physically more accurate and produces satisfactory results efficiently.

Keywords: Multi-block algorithm, conservation, interpolation, numerical model, flow simulation.

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Authors: Oke Oktavianty, Tadayuki Kyoutani, Shigeyuki Haruyama, Junji Kaneko, Ken Kaminishi

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Modelica has many advantages and it is very useful in modeling and simulation especially for the multi-domain with a complex technical system. However, the big obstacle for a beginner is to understand the basic concept and to build a new system model for a real system. In order to understand how to solve the simple circuit model by hand translation and to get a better understanding of how modelica works, we provide a detailed explanation about solver ordering system in horizontal and vertical sorting and make some proposals for improvement. In this study, some difficulties in using modelica software with the original concept and the comparison with Finite Element Method (FEM) approach is discussed. We also present our textual modeling approach using FEM concept for acausal and causal model construction. Furthermore, simulation results are provided that demonstrate the comparison between using textual modeling with original coding in modelica and FEM concept.

Keywords: FEM, acausal model, modelica, horizontal and vertical sorting.

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Authors: R. M. Barron, B. Zogheib

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A new numerical method for solving the twodimensional, steady, incompressible, viscous flow equations on a Curvilinear staggered grid is presented in this paper. The proposed methodology is finite difference based, but essentially takes advantage of the best features of two well-established numerical formulations, the finite difference and finite volume methods. Some weaknesses of the finite difference approach are removed by exploiting the strengths of the finite volume method. In particular, the issue of velocity-pressure coupling is dealt with in the proposed finite difference formulation by developing a pressure correction equation in a manner similar to the SIMPLE approach commonly used in finite volume formulations. However, since this is purely a finite difference formulation, numerical approximation of fluxes is not required. Results obtained from the present method are based on the first-order upwind scheme for the convective terms, but the methodology can easily be modified to accommodate higher order differencing schemes.

Keywords: Curvilinear, finite difference, finite volume, SIMPLE.

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Authors: E T. Rakgati, E. Matlotse

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In this paper the principle, basic torque theory and design optimisation of a six-phase reluctance dc machine are considered. A trapezoidal phase current waveform for the machine drive is proposed and evaluated to minimise ripple torque. Low cost normal laminated salient-pole rotors with and without slits and chamfered poles are investigated. The six-phase machine is optimised in multi-dimensions by linking the finite-element analysis method directly with an optimisation algorithm; the objective function is to maximise the torque per copper losses of the machine. The armature reaction effect is investigated in detail and found to be severe. The measured and calculated torque performances of a 35 kW optimum designed six-phase reluctance dc machine drive are presented.

Keywords: Reluctance dc machine, current waveform, design optimisation, finite element analysis, armature reaction effect.

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Authors: Maziar Ramezani, Thomas Neitzert

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This paper gives an overview of a deep drawing process by pressurized liquid medium separated from the sheet by a rubber diaphragm. Hydroforming deep drawing processing of sheet metal parts provides a number of advantages over conventional techniques. It generally increases the depth to diameter ratio possible in cup drawing and minimizes the thickness variation of the drawn cup. To explore the deformation mechanism, analytical and numerical simulations are used for analyzing the drawing process of an AA6061-T4 blank. The effects of key process parameters such as coefficient of friction, initial thickness of the blank and radius between cup wall and flange are investigated analytically and numerically. The simulated results were in good agreement with the results of the analytical model. According to finite element simulations, the hydroforming deep drawing method provides a more uniform thickness distribution compared to conventional deep drawing and decreases the risk of tearing during the process.

Keywords: Deep drawing, Hydroforming, Rubber diaphragm

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Authors: J. Arashmehr, G. H. Rahimi, S.F.Rasouli

Abstract:

Grid composite structures have many applications in aerospace industry in which deal with transverse loadings abundantly. In present paper a stiffened composite cylindrical shell with clamped-free boundary condition under transverse end load experimentally and numerically was studied. Some electrical strain gauges were employed to measure the strains. Also a finite element analysis was done for validation of experimental result. The FEM software used was ANSYS11. In addition, the results between stiffened composite shell and unstiffened composite shell were compared. It was observed that intersection of two stiffeners has an important effect in decrease of stress in the shell. Fairly good agreements were observed between the numerical and the measured results. According to recent studies about grid composite structures, it should be noted that any investigation like this research has not been reported.

Keywords: Grid composite structure, Transverse loadings, Strain measurement, Finite element analysis

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Authors: R. Kiruthika, T. Shanmuganantham

Abstract:

A shaped single feed microstrip antenna is realized for C-Band and X-Band applications. The frequency range of C-band and X-band varies from 4 to 8 Gigahertz and 8 to 12 Gigahertz. The antenna operates under three frequency bands, one under C band and two under X-band applications. Defect on the ground called DGS (Defected Ground Structure) is made to enhance the distinctiveness of the antenna parameters. The design consists of DGS provided to improve the antenna performance. The substrate material used is of the Flame Retardant grade-4 (FR4) epoxy having high mechanical and electrical strength. The design and analysis was done using the FEM (Finite Element Method) based Ansoft HFSS (High Frequency Structural Simulator) Version 12. For the resonant frequencies of 5.21, 9.17 and 10.45, a value of reflection coefficient obtained is of -39.0, -16.0 and -30.7 dB respectively. Other constraints of antenna such as bandwidth, gain, directivity and Voltage Standing Wave Ratio (VSWR) are also conferred.

Keywords: Flame retardant-4 epoxy, finite element method, return loss, directivity.

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Authors: Jeong-Woo Seo, Jin-Seung Choi, Dong-Won Kang, Jae-Hyuk Bae, Gye-Rae Tack

Abstract:

To achieve accurate and precise results of finite element analysis (FEA) of bones, it is important to represent the load/boundary conditions as identical as possible to the human body such as the bone properties, the type and force of the muscles, the contact force of the joints, and the location of the muscle attachment. In this study, the difference in the Von-Mises stress and the total deformation was compared by classifying them into Case 1, which shows the actual anatomical form of the muscle attached to the femur when the same muscle force was applied, and Case 2, which gives a simplified representation of the attached location. An inverse dynamical musculoskeletal model was simulated using data from an actual walking experiment to complement the accuracy of the muscular force, the input value of FEA. The FEA method using the results of the muscular force that were calculated through the simulation showed that the maximum Von-Mises stress and the maximum total deformation in Case 2 were underestimated by 8.42% and 6.29%, respectively, compared to Case 1. The torsion energy and bending moment at each location of the femur occurred via the stress ingredient. Due to the geometrical/morphological feature of the femur of having a long bone shape when the stress distribution is wide, as shown in Case 1, a greater Von-Mises stress and total deformation are expected from the sum of the stress ingredients. More accurate results can be achieved only when the muscular strength and the attachment location in the FEA of the bones and the attachment form are the same as those in the actual anatomical condition under the various moving conditions of the human body.

Keywords: Musculoskeletal modeling, Finite element analysis, Von-Mises stress, Deformation, Muscle attachment.

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Authors: Sh. Shahhosseini, S. Alinia, M. Irani

Abstract:

In this paper 2D Simulation of catalytic Fixed Bed Reactor in Fischer-Tropsch Synthesis of GTL technology has been performed utilizing computational fluid dynamics (CFD). Synthesis gas (a mixture of carbon monoxide and hydrogen) has been used as feedstock. The reactor was modeled and the model equations were solved employing finite volume method. The model was validated against the experimental data reported in literature. The comparison showed a good agreement between simulation results and the experimental data. In addition, the model was applied to predict the concentration contours of the reactants and products along the length of reactor.

Keywords: GTL, Fischer–Tropsch synthesis, Fixed Bed Reactor, CFD simulation.

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Authors: Emanuela Paranhos Lima, Vitaly Félix Rodríguez Esquerre

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In this work, efficient directional coupler composed of dielectric waveguides and metallic film has been analyzed in details by simulations using finite element method (FEM). The structure consists of a step-index fiber with dielectric core, silica cladding, and a metal nanowire parallel to the core. The results show that an efficient conversion of optical dielectric modes to long range plasmonic is possible. Low insertion losses in conjunction with short coupling length and a broadband operation can be achieved under certain conditions. This kind of couplers has potential applications for the design of photonic integrated circuits for signal routing between dielectric/plasmonic waveguides, sensing, lithography, and optical storage systems. A high efficient focusing of light in a very small region can be obtained.

Keywords: Directional coupler, finite element method, metallic nanowire, plasmonic, surface plasmon polariton.

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Authors: Saroj Kumar Sarangi, M. C. Ray

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This paper deals with the analysis of active constrained layer damping (ACLD) of doubly curved laminated composite shells using active fiber composite (AFC) materials. The constraining layer of the ACLD treatment has been considered to be made of the AFC materials. A three dimensional energy based finite element model of the smart doubly curved laminated composite shell integrated with a patch of such ACLD treatment has been developed to demonstrate the performance of the patch on enhancing the damping characteristics of the doubly curved laminated composite shells. Particular emphasis has been placed on studying the effect of variation of piezoelectric fiber orientation angle in the constraining AFC layer on the control authority of the ACLD patch.

Keywords: Active constrained layer damping, Active fibercomposites, Finite element modeling, First order shear deformationtheory.

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Authors: Shitian Liu, Deqin Chen

Abstract:

Let G be a finite group, and let F be a formation of finite group. We say that a subgroup H of G is p F -normal in G if there exists a normal subgroup T of G such that HT is a permutable Hall subgroup of G and G G (H

Keywords: Finite group, Fp -normal subgroup, Sylowsubgroup, Maximal subgroup

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Authors: N. K. Paul, S. Saha

Abstract:

An innovative three dimensional finite element model has beed developed and tested under two point loading system to examine the structural behavior of the longitudinal reinforced concrete Tee-beam bridge girder, reinforcing with steel and shape memory alloy bars respectively. 25% of steel bars are replaced with superelastic Shape Memory Alloy bars in this study. Finite element analysis is performed using ANSYS 11.0 program. Experimentally a model of steel reinforced girder has been casted and its load deflection responses are checked with ANSYS analysis. A comparison of load carrying capacity for the model between steel RC girder and the girder combined reinforcement with SMA and steel are also performed.

Keywords: Shape memory alloy, bridge girder, ANSYS, load-deflection.

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Authors: Theddeus T. Akano, Omotayo A. Fakinlede

Abstract:

The modelling of physical phenomena, such as the earth’s free oscillations, the vibration of strings, the interaction of atomic particles, or the steady state flow in a bar give rise to Sturm- Liouville (SL) eigenvalue problems. The boundary applications of some systems like the convection-diffusion equation, electromagnetic and heat transfer problems requires the combination of Dirichlet and Neumann boundary conditions. Hence, the incorporation of Robin boundary condition in the analyses of Sturm-Liouville problem. This paper deals with the computation of the eigenvalues and eigenfunction of generalized Sturm-Liouville problems with Robin boundary condition using the finite element method. Numerical solution of classical Sturm–Liouville problem is presented. The results show an agreement with the exact solution. High results precision is achieved with higher number of elements.

Keywords: Sturm-Liouville problem, Robin boundary condition, finite element method, eigenvalue problems.

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Authors: M. E. Abou-Hashem El Dib, M. K. Swailem, M. M. Metwally, A. I. El Awady

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This paper presents the effect of stiffeners on the behavior of slender steel I-beams. Nonlinear three dimensional finite element models are developed to represent the stiffened steel I-beams. The well established finite element (ANSYS 13.0) program is used to simulate the geometric and material nonlinear nature of the problem. Verification is achieved by comparing the obtained numerical results with the results of previous published experimental work. The parameters considered in the analysis are the horizontal stiffener's position and the horizontal stiffener's dimensions as well as the number of vertical stiffeners. The studied dimensions of the horizontal stiffeners include the stiffener width, the stiffener thickness and the stiffener length. The results of the achieved numerical parametric study for slender steel I-beams show the significant effect of stiffeners on the beam behavior and its failure load.

Keywords: Steel I-beams, local buckling, slender, stiffener, thin walled section.

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Authors: M. Pasbani Khiavi, A. R. M. Gharabaghi, K. Abedi

Abstract:

The mechanical behavior of porous media is governed by the interaction between its solid skeleton and the fluid existing inside its pores. The interaction occurs through the interface of gains and fluid. The traditional analysis methods of porous media, based on the effective stress and Darcy's law, are unable to account for these interactions. For an accurate analysis, the porous media is represented in a fluid-filled porous solid on the basis of the Biot theory of wave propagation in poroelastic media. In Biot formulation, the equations of motion of the soil mixture are coupled with the global mass balance equations to describe the realistic behavior of porous media. Because of irregular geometry, the domain is generally treated as an assemblage of fmite elements. In this investigation, the numerical formulation for the field equations governing the dynamic response of fluid-saturated porous media is analyzed and employed for the study of transient wave motion. A finite element model is developed and implemented into a computer code called DYNAPM for dynamic analysis of porous media. The weighted residual method with 8-node elements is used for developing of a finite element model and the analysis is carried out in the time domain considering the dynamic excitation and gravity loading. Newmark time integration scheme is developed to solve the time-discretized equations which are an unconditionally stable implicit method Finally, some numerical examples are presented to show the accuracy and capability of developed model for a wide variety of behaviors of porous media.

Keywords: Dynamic analysis, Interaction, Porous media, time domain

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Authors: R. Ziaie Moayed , S. Tamassoki , E. Izadi

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Investigation of sandy clay behavior is important since urban development demands mean that sandy clay areas are increasingly encountered, especially for transportation infrastructures. This paper presents the results of the finite element analysis of the direct shear test (under three vertical loading 44, 96 and 192 kPa) and discusses the effects of different parameters such as cohesion, friction angle and Young's modulus on the shear strength of sandy clay. The numerical model was calibrated against the experimental results of large-scale direct shear tests. The results have shown that the shear strength was increased with increase in friction angle and cohesion. However, the shear strength was not influenced by raising the friction angle at normal stress of 44 kPa. Also, the effect of different young's modulus factors on stress-strain curve was investigated.

Keywords: Shear strength, Finite element analysis, Large direct shear test, Sandy clay.

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Authors: T.C. Manjunath, B. Bandyopadhyay

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This paper features the proposed modeling and design of a Robust Decentralized Periodic Output Feedback (RDPOF) control technique for the active vibration control of smart flexible multimodel Euler-Bernoulli cantilever beams for a multivariable (MIMO) case by retaining the first 6 vibratory modes. The beam structure is modeled in state space form using the concept of piezoelectric theory, the Euler-Bernoulli beam theory and the Finite Element Method (FEM) technique by dividing the beam into 4 finite elements and placing the piezoelectric sensor / actuator at two finite element locations (positions 2 and 4) as collocated pairs, i.e., as surface mounted sensor / actuator, thus giving rise to a multivariable model of the smart structure plant with two inputs and two outputs. Five such multivariable models are obtained by varying the dimensions (aspect ratios) of the aluminum beam, thus giving rise to a multimodel of the smart structure system. Using model order reduction technique, the reduced order model of the higher order system is obtained based on dominant eigen value retention and the method of Davison. RDPOF controllers are designed for the above 5 multivariable-multimodel plant. The closed loop responses with the RDPOF feedback gain and the magnitudes of the control input are observed and the performance of the proposed multimodel smart structure system with the controller is evaluated for vibration control.

Keywords: Smart structure, Euler-Bernoulli beam theory, Periodic output feedback control, Finite Element Method, State space model, SISO, Embedded sensors and actuators, Vibration control, Reduced order model

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Authors: Jui P. Hung, Yuan L. Lai, Tzuo L. Luo, Hsi H. Hsiao

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The machining performance is determined by the frequency characteristics of the machine-tool structure and the dynamics of the cutting process. Therefore, the prediction of dynamic vibration behavior of spindle tool system is of great importance for the design of a machine tool capable of high-precision and high-speed machining. The aim of this study is to develop a finite element model to predict the dynamic characteristics of milling machine tool and hence evaluate the influence of the preload of the spindle bearings. To this purpose, a three dimensional spindle bearing model of a high speed engraving spindle tool was created. In this model, the rolling interfaces with contact stiffness defined by Harris model were used to simulate the spindle bearing components. Then a full finite element model of a vertical milling machine was established by coupling the spindle tool unit with the machine frame structure. Using this model, the vibration mode that had a dominant influence on the dynamic stiffness was determined. The results of the finite element simulations reveal that spindle bearing with different preloads greatly affect the dynamic behavior of the spindle tool unit and hence the dynamic responses of the vertical column milling system. These results were validated by performing vibration on the individual spindle tool unit and the milling machine prototype, respectively. We conclude that preload of the spindle bearings is an important component affecting the dynamic characteristics and machining performance of the entire vertical column structure of the milling machine.

Keywords: Dynamic compliance, Milling machine, Spindle unit, Bearing preload.

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Authors: Sharon S. Wu, Yong S. Park

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This project aims to study and evaluate the motorcycle crash bar, which is used to reduce injuries caused by side impacts to the motorcycle, and then develop an improved design using the engineering design process theory based on the current benchmark crash bar in order to lower the severity of motorcycle crash injuries. For this purpose, simulations for the crash bar are set up so that it travels at an angle towards a fixed concrete wall and collides at certain velocities. 3D CAD models are first designed in SolidWorks and dynamic crash simulations are then carried out using ANSYS to determine the lowest maximum Von-Mises stress over time and deformations by adjusting the parameters used in manufacturing the crash bar, including the velocity of the crash, material used, geometries with various radius fillets, and different thicknesses for the bar. The results of the simulation are used to determine the optimum parameters for a safer crash bar to withstand higher stress and deformation. Specifically, the von-Mises stress was reduced by at least 75% compared with the benchmark design by choosing aluminum alloy and a true unibar design.

Keywords: Crash bar, crash simulation, engineering design, motorcycle safety.

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Authors: I. Made Gatot Karohika, Shigeyuki Haruyama, Ken Kaminishi, Oke Oktavianty, Didik Nurhadiyanto

Abstract:

Contact width and contact stress are important parameters related to the leakage behavior of corrugated metal gasket. In this study, contact width and contact stress of three-layer corrugated metal gasket are investigated due to the modulus of elasticity and thickness of surface layer for 2 type gasket (0-MPa and 400-MPa mode). A finite element method was employed to develop simulation solution to analysis the effect of each parameter. The result indicated that lowering the modulus of elasticity ratio of surface layer will result in better contact width but the average contact stresses are smaller. When the modulus of elasticity ratio is held constant with thickness ratio increase, its contact width has an increscent trend otherwise the average contact stress has decreased trend.

Keywords: Contact width, contact stress, layer, metal gasket, corrugated, simulation.

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Authors: Guray Arslan, Riza S. O. Keskin

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Numerical investigations were conducted to study the influence of flexural reinforcement ratio on the diagonal cracking strength and ultimate shear strength of reinforced concrete (RC) beams without stirrups. Three-dimensional nonlinear finite element analyses (FEAs) of the beams with flexural reinforcement ratios ranging from 0.58% to 2.20% subjected to a mid-span concentrated load were carried out. It is observed that the load-deflection and loadstrain curves obtained from the numerical analyses agree with those obtained from the experiments. It is concluded that flexural reinforcement ratio has a significant effect on the shear strength and deflection capacity of RC beams without stirrups. The predictions of diagonal cracking strength and ultimate shear strength of beams obtained by using the equations defined by a number of codes and researchers are compared with each other and with the experimental values.

Keywords: Finite element, flexural reinforcement, reinforced concrete beam, shear strength.

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Authors: Tatyana R. Radeva, Ivan S. Yatchev, Dimitar N. Karastoyanov, Nikolay I. Stoimenov, Stanislav D. Gyoshev

Abstract:

The paper presents coupled electromagnetic and thermal field analysis of busbar system (of rectangular cross-section geometry) submitted to short circuit conditions. The laboratory model was validated against both analytical solution and experimental observations. The considered problem required the computation of the detailed distribution of the power losses and the heat transfer modes. In this electromagnetic and thermal analysis, different definitions of electric busbar heating were considered and compared. The busbar system is a three phase one and consists of aluminum, painted aluminum and copper busbar. The solution to the coupled field problem is obtained using the finite element method and the QuickField™ program. Experiments have been carried out using two different approaches and compared with computed results.

Keywords: Busbar system, coupled problems, finite element method, short-circuit currents.

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Authors: H.Mohammadi Majd, M.Jalali Azizpour

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In this paper back-propagation artificial neural network (BPANN )with Levenberg–Marquardt algorithm is employed to predict the deformation of the upsetting process. To prepare a training set for BPANN, some finite element simulations were carried out. The input data for the artificial neural network are a set of parameters generated randomly (aspect ratio d/h, material properties, temperature and coefficient of friction). The output data are the coefficient of polynomial that fitted on barreling curves. Neural network was trained using barreling curves generated by finite element simulations of the upsetting and the corresponding material parameters. This technique was tested for three different specimens and can be successfully employed to predict the deformation of the upsetting process

Keywords: Back-propagation artificial neural network(BPANN), prediction, upsetting

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Authors: Essam A. Al-Bahkali

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A three-dimensional finite element modeling for austenitic stainless steel AISI 304 annealed condition sheets of 1.0 mm thickness are developed using ABAQUS® software. This includes spot welded and weld bonded joints models. Both models undergo thermal heat caused by spot welding process and then are subjected to axial load up to the failure point. The properties of elastic and plastic regions, modulus of elasticity, fracture limit, nugget and heat affected zones are determined. Complete loaddisplacement curve for each joining model is obtained and compared with the experiment data and with the finite element models without including the effect of thermal process. In general, the results obtained for both spot welded and weld-bonded joints affected by thermal process showed an excellent agreement with the experimental data.

Keywords: Heat Affected Zone, Spot Welded, Thermal Process, Weld-Bonded.

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Authors: Masoud Mohammadpour, Blair Carlson, Radovan Kovacevic

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The quality of laser welded-brazed (LWB) joints were strongly dependent on the main process parameters, therefore the effect of laser power (3.2–4 kW), welding speed (60–80 mm/s) and wire feed rate (70–90 mm/s) on mechanical strength and surface roughness were investigated in this study. The comprehensive optimization process by means of response surface methodology (RSM) and desirability function was used for multi-criteria optimization. The experiments were planned based on Box– Behnken design implementing linear and quadratic polynomial equations for predicting the desired output properties. Finally, validation experiments were conducted on an optimized process condition which exhibited good agreement between the predicted and experimental results. AlSi3Mn1 was selected as the filler material for joining aluminum alloy 6022 and hot-dip galvanized steel in coach peel configuration. The high scanning speed could control the thickness of IMC as thin as 5 µm. The thermal simulations of joining process were conducted by the Finite Element Method (FEM), and results were validated through experimental data. The Fe/Al interfacial thermal history evidenced that the duration of critical temperature range (700–900 °C) in this high scanning speed process was less than 1 s. This short interaction time leads to the formation of reaction-control IMC layer instead of diffusion-control mechanisms.

Keywords: Laser welding-brazing, finite element, response surface methodology, multi-response optimization, cross-beam laser.

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