Load-cell-design developments by numerical and experimental methods

Design data for a family of ring-shaped elastic elements are derived using analytical, numerical and experimental methods. The development of a family of elastic elements for load cells operating at medium to low load level is considered in detail, using several approaches. Snapes analyzed were circular ring with integral bosses and ‘square’ ring. The effects of thickness, boss size and fillet radius (reduced to nondimensional form) on strain/load and defiection/load relationships are evaluated within a given sample space, considering a two-dimensional problem. Thin-ring and curved-beam theory support the analytical approach, with correction terms covering some departures from theoretical shape. Numerical analysis with the finite-element method was mainly used to evaluate the effects of boss size and shape. Accordingly, the required grid patterns were developed using a mesh-generating method capable of covering the range of parameters considered. A set of configurations was selected, enabling single and combined effects to be analyzed with little entanglement between estimates. For the square ring, frame theory and a limit solution for the case of the plate with central hole are resorted to. Photoelastic tests were performed, covering a range of shapes by sequential remachining of the model, and equal contigurations were analyzed with the finite-element method. Strain-gage tests on actual elastic elements were made, considering also the results of a series of tests carried out at the Metrology Institute some time ago. Results obtained yield comprehensive information on the effect of several parameters on the load-output transfer function of ring-shaped elastic elements.     

Theoretical and numerical analysis of the corneal air puff test

Ocular analyzers are used in the current clinical practice to estimate, by means of a rapid air jet, the intraocular pressure and other eye's parameters. In this study, we model the biomechanical response of the human cornea to the dynamic test with two approaches. In the first approach, the corneal system undergoing the air puff test is regarded as a harmonic oscillator. In the second approach, we use patient-specific geometries and the finite element method to simulate the dynamic test on surgically treated corneas. In spite of the different levels of approximation, the qualitative response of the two models is very similar, and the most meaningful results of both models are not significantly affected by the inclusion of viscosity of the corneal material in the dynamic analysis. Finite element calculations reproduce the observed snap-through of the corneal shell, including two applanate configurations, and compare well with in vivo images provided by ocular analyzers, suggesting that the mechanical response of the cornea to the air puff test is actually driven only by the elasticity of the stromal tissue. These observations agree with the dynamic characteristics of the test, since the frequency of the air puff impulse is several orders of magnitude larger than the reciprocal of any reasonable relaxation time for the material, downplaying the role of viscosity during the fast snap-through phase.     

An experimental and numerical investigation of different shear test configurations for sheet metal characterization

Simple shear tests are widely used for material characterization especially for sheet metals to achieve large deformations without plastic instability. This work describes three different shear tests for sheet metals in order to enhance the knowledge of the material behavior under shear conditions. The test setups are different in terms of the specimen geometry and the fixtures. A shear test setup as proposed by Miyauchi, according to the ASTM standard sample, as well as an in-plane torsion test are compared in this study. A detailed analysis of the experimental strain distribution measured by digital image correlation is discussed for each test. Finite element simulations are carried out to evaluate the effect of specimen geometries on the stress distributions in the shear zones. The experimental macroscopic flow stress vs. strain behavior shows no significant influence of the specimen geometry when similar strain measurements and evaluation schemes are used. Minor differences in terms of the stress distribution in the shear zone can be detected in the numerical results. This work attempts to give a unique overview and a detailed study of the most commonly used shear tests for sheet metal characterization. It also provides information on the applicability of each test for the observation of the material behavior under shear stress with a view to material modeling for finite element simulations.     

A thin-plate analysis and experimental evaluation of couple-stress effects

Couple-stress effects in materials have received much theoretical consideration recently but little or no experimental verification. The first part of this paper deals with a simplified elastic analysis for thin plates with couple stress which should provide a simple experimental approach to the determination of the order of magnitude of these effects. Classical concepts were utilized where applicable and many existing solutions can be modified by the present analysis to include couple stress. In the second part, experiments approximating cylindrical bending were carried out on plates of commercial-grade low-carbon steel and high-purity aluminum in the annealed and wrought conditions in order to establish the order of magnitude of the couple stress constantl as found in a simple couple-stress theory. Results were compared with classical theory and other experimental data correlated by the Neuber method to determine whether or not the couple-stress effect as predicted by a simple couple-stress theory could account for the reduction in the stress concentration found for small-radius notches and holes. It was found that the order of magnitude ofl was not greater than 0.002 in. rather than 0.02 in. as would be required to explain the above-mentioned reduction in stress concentration. Since the grain size of those materials was also ?0.002 in., it was concluded that:

1. (a)
   Couple-stress effects predicted by a simple theory were not significant enough to account for the reduction of stress concentration noted above for the material tested.     
   
   

静压沉桩挤土机理探讨及有限元分析

针对预制桩在静压沉桩过程中出现的挤土现象,从土体小主应力方向加载的角度考虑,视浅层土体的隆起为小主应力方向(水平向)加载引起大主应力(垂直向应力)增加所致.在已有的柱形小孔扩张理论基础上,通过引入考虑位移的土压力计算方法提出了桩周土体隆起分界面表达式.利用该表达式分析浅层土体的隆起量,并利用Randolph提出的深层土体径向位移解析公式给出深层土体的变形量.最后运用有限元数值模拟计算与本文的数值解答进行对比分析,结果相近.     

An experimental evaluation of the slotted-tension shear test for composite materials

The slotted-tension shear test provides an accurate method of measuring the inplane shear response of fiber-reinforced composite materials. Data from the slotted-tension test is compared with rail, ±45-deg tension, modified lap-shear and off-axis shear tests. It is shown that reinforced materials of any combination of fibers and fiber orientation can be tested using the new shear-testing technique.     

A numerical and experimental analysis of the process of water vapour absorption by a static lithium bromide solution

This paper describes a numerical and experimental analysis of the process of water vapour absorption by a static lithium bromide solution. In the experiment, the temperature evolution of the absorbent solution is measured at different heights. The numerical model solves the set of governing equations for the simultaneous heat and mass transfer inside the absorbent by means of the finite-volume method. An iterative method is used to take into account the strong coupling of heat and mass transfer at the interface and variations of thermophysical properties. A moving grid technique is employed to represent the increase of the solution volume. Model results are compared with our measurements and data reported in the literature. The influence of using constant properties is analysed by comparison with the variable properties and experimental results. It is found that this assumption provides acceptable results in the investigated pool absorption cases despite a strong underestimation of the increase of the solution volume in the course of the absorption process.     

Thermal reliability analysis of a BLDC motor in a high-speed axial fan by the accelerated-life test and numerical methods

The thermal reliability of a closed-type BLDC motor for a high-speed fan is analyzed by an accelerated-life testing and numerical methods in this paper. Since a module and a motor part are integrated in a closed case, heat generated from a rotor in a motor and electronic components in the PCB module cannot be effectively removed to the outside. Therefore, the module will easily fail due to high temperature. The experiment for measuring the temperature and the surface heat flux of the electronic components is carried out to predict their surface temperature distributions and main heat sources. The accelerated-life test is accomplished to formulate the life equation depending on the environmental temperature. Moreover, the temperature of the PCB module is different from the environmental temperature since the heat generated from the motor cannot be effectively dissipated owing to the motor’s structure. Therefore a numerical method is used to predict the temperature of the PCB module, which is one of the life equation parameter, according to the environment. By numerically obtaining the maxima of the thermal stress and strain of the electronic components according to the operation environments with the temperature results, the fatigue cycle can be estimated.     

海洋系泊链钢22MnCrNiMo腐蚀磨损试验与数值分析研究

建立了锚链在海洋环境中腐蚀磨损(简称"磨蚀")累积损伤数值分析方法,该方法采用非线性有限元分析,能够同时考虑锚链链环间接触面在海水中的腐蚀和磨损耦合损伤。针对22MnCrNiMo低碳低合金钢材料,进行了力学性能、海水侵蚀以及磨蚀性能等多方面的试验研究,确定了基于该材料的锚链链环间接触面在海水中磨蚀损伤数值分析中的相关参数。通过对计算结果与试验结果的比较分析,验证了锚链链环间接触面磨蚀累积损伤数值分析方法的可行性与准确性。     

Integrated numerical–experimental analysis of interfacial fatigue fracture in SnAgCu solder joints

In ball grid array (BGA) packages, solder balls are exposed to cyclic thermo-mechanical strains arising from the thermal mismatch between package components. Thermo-mechanical fatigue crack propagation in solder balls is almost always observed at the chip side of the bump/pad junction. The objective of the experimental part of this study is to characterize the bump/pad interface under fatigue loading. Fatigue specimens are prepared by reflowing Sn3.8Ag0.5Cu lead-free solder alloy on Ni/Au substrates. Obtained results show that fatigue damage evolution strongly depends on the microstructure. Applied strain and solder volume both have an influence on the fatigue damage mechanism. In the numerical part of the study, fatigue experiments are modeled using the finite element technique. A cohesive zone approach is used to predict the fatigue damage evolution in soldered connections. Crack propagation is simulated by an irreversible linear traction–separation cohesive zone law accompanied by a non-linear damage parameter. Cohesive zone elements are placed where failure is experimentally observed. Damage evolution parameters for normal and tangential interaction are scrutinized through dedicated fatigue tests in pure tensile and shear directions. The proposed cohesive zone model is quantitatively capable of describing fatigue failure in soldered joints, which can be further extended to a numerical life-time prediction tool in microelectronic packages.     

基于SPH方法粒子射流破岩数值模拟与实验研究

钻井液中加入体积分数为1%~3%的钢质粒子在钻头喷嘴处高速喷出冲击岩石,实现了粒子射流冲击和钻头机械联合破岩,有效提高了破岩效率。利用瞬态非线性动力学有限元模拟软件,基于光滑粒子流体动力学(smoothed particle hydrodynamics,SPH)方法,考虑流体对粒子射流冲击的影响,建立了粒子射流冲击破岩的物理模型,获得了粒子射流参数对破岩体积的影响规律,进行了室内实验验证,验证了SPH方法的有效性。结果表明:粒子射流冲击岩石表面形成规则的V型冲击坑;同条件下粒子射流破岩体积是水射流破岩体积的2~4倍;随着粒子射流冲蚀时间的增加,粒子射流破岩体积不断增加,但破岩效率降低;粒子射流压力大于10 MPa后,粒子射流破岩效率迅速增大;喷射角度大于6°后,破岩效率迅速减小。     

Higher-order numerical differentiation of experimental information

Cubic-spline and discrete-quadratic polynomial techniques are presented for reliably computing up to third-order derivatives of experimental information. The concept is demonstrated by stress analyzing from measured displacements a transversely loaded plate and a beam under four-point bending. The respective displacement fields were recorded using holography and moiré. The accuracy of the employed numerical-differentiation techniques is indicated.     

Configuration-dependent modal analysis of a Cartesian parallel kinematics manipulator: numerical modeling and experimental validation

In the design optimization of a robot the configuration-dependent modal analysis can be a powerful tool to be exploited when high stiffness and high dynamic performances are concurrently required. In this paper the elastodynamics of a lower-mobility Parallel Kinematic Machine for pure translational motions is analyzed. The vibrational modes and the natural frequencies of the robot are evaluated as functions of the end effector position inside the workspace. A finite element model including kinematic joints is used to perform a series of modal analyses in a grid of points inside the workspace. A polynomial regression gives continuous volume maps of the natural frequencies distributions. The numerical model is validated by comparison with experiments: a modal analysis is conducted on a set of inertance Frequency Response Functions acquired on several points of the machine components as a result of an excitation given by an instrumented hammer. A Natural Frequency Difference analysis validates the model under certain conditions and highlights some critical issues to be focused on in future works.     

海洋平台K型管节点的疲劳裂纹扩展分析I:试验测试

对承受疲劳载荷的海洋平台K型管节点首先进行了静力测试,确定了沿着焊缝的热应力区的应力分布及热应力区最大应力点的位置,从而判断裂纹产生的位置;然后通过专用测试设备提供循环疲劳载荷,用ACPD(Alternating Current Potential Drop,即交流电流势能落差法)技术检测裂纹的产生和增长过程,得到裂纹最深点,用S-N曲线估算其疲劳寿命.对已有裂纹的K型管节点,用应力强度因子估计其剩余寿命.同时用测试的结果验证了S-N的准确性和可靠性.     

复合射孔压力加载下铜柱测压计测试实验和数值分析

进行基于铜柱测压和实测压力时间曲线的石油井射孔压裂实验,建立铜柱测压计的数学模型,并采用交互式计算方法得出其作用过程的解析解。分析结果表明,井下射孔压裂过程中,压力上升沿很陡,活塞在外部压力达到峰值时,速度很大,会继续压缩铜柱直到速度为零。活塞的运动可以分为加速和减速撞击2个过程。活塞的最大速度决定了铜柱测压计最终测试值,且与速度成正比。射孔脉冲压力加载过程中铜柱测压计的误差取决于压力上升时间、脉冲宽度、峰值压力等影响因素。火炮膛压加载下铜柱测压计误差较小。     

Capturing the experimental behaviour of a point-absorber WEC by simplified numerical models

The paper presents a wave basin experiment of a direct-driven point-absorber wave energy converter moving in six degrees of freedom. The goal of the work is to study the dynamics and energy absorption of the wave energy converter, and to verify under which conditions numerical models restricted to heave can capture the behaviour of a point-absorber moving in six degrees of freedom. Several regular and irregular long-crested waves and different damping values of the power take-off system have been tested. We collected data in terms of power output, device motion in six degrees of freedom and wave elevation at different points of the wave basin. A single-body numerical model in the frequency domain and a two-body model in the time domain are used in the study. Motion instabilities due to parametric resonance observed during the experiments are discussed and analysis of the buoy motion in terms of the Mathieu instability is also presented. Our results show that the simplified models can reproduce the body dynamics of the studied converter as long as the transverse non-linear instabilities are not excited, which typically is the case in irregular waves. The performance of the more complex time domain model is able to reproduce both the buoy and PTO dynamics, while the simpler frequency domain model can only reproduce the PTO dynamics for specific cases. Finally, we show that the two-body dynamics of the studied wave energy converter affects the power absorption significantly, and that common assumptions in the numerical models, such as stiff mooring line or that the float moves only in heave, may lead to incorrect predictions for certain sea states.     

Direct numerical test of the B-G-K model equation by the DSMC method

In the present paper the rarefied gas flow caused by the sudden change of the wall temperature and the Rayleigh problem are simulated by the DSMC method which has been validated by experiments both in global flow field and velocity distribution function level. The comparison of the simulated results with the accurate numerical solution of the B-G-K model equation shows that near equilibrium the B-G-K equation with corrected collision frequency can give accurate result but as farther away from equilibrium the B-G-K equation is not accurate. This is for the first time that the error caused by the B-G-K model equation has been revealed. The project supported by the National Natural Science Foundation of China (19772059, 19889209)     

Numerical analysis of the effects induced by normal faults and dip angles on rock bursts

The study of mining effects under the influences of a normal fault and its dip angle is significant for the prediction and prevention of rock bursts. Based on the geological conditions of panel 2301N in a coalmine, the evolution laws of the strata behaviors of the working face affected by a fault and the instability of the fault induced by mining operations with the working face of the footwall and hanging wall advancing towards a normal fault are studied using UDEC numerical simulation. The mechanism that induces rock burst is revealed, and the influence characteristics of the fault dip angle are analyzed. The results of the numerical simulation are verified by conducting a case study regarding the microseismic events. The results of this study serve as a reference for the prediction of rock bursts and their classification into hazardous areas under similar conditions.     

An analytical and experimental stress analysis of a practical mode II fracture test specimen

A boundary-collocation method has been employed to determine the Mode II stress-intensity factors for a pair of through-the-thickness edge cracks in a finite isotropic plate. An elastostatic analysis has been carried out in terms of the complete Williams stress function employing both even and old components. The results of the numerical analysis were verified by a two-step procedure whereby the symmetric (Mode I) and antisymmetric (Mode II) portions of the solution were independently compared with existing solutions. Since no previous analytical solutions existed for the asymmetric loading of an edge-cracked plate, the complete solution was verified by comparison with a photoelastic analysis. A compact shear (CS) specimen of Hysol epoxy resin was loaded in a photoelastic experiment designed to study the isochromatic-fringe patterns resulting from the Mode II crack-tip stress distribution. The experiment verified that a pure mode II stress distribution existed in the neighborhood of the crack tips, and confirmed the accuracy of the boundary-collocation solution for the Mode II stress-intensity factors. Specimen center-line stress-distribution data were obtained photoelastically and employed to refine the boundary-collocation analysis. Agreement between the analytically and experimentally determined Mode II stress-intensity factors was excellent.