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Keywords = finite element method

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18 pages, 5509 KiB  
Article
Scenarios of Progressive Pancake/Bending Collapse Considering Elastic/Plastic Reinforced Concrete Buildings
by Enrico Zacchei and Caio Gorla Nogueira
Buildings 2024, 14(7), 1948; https://doi.org/10.3390/buildings14071948 (registering DOI) - 27 Jun 2024
Abstract
Quantitative analyses of structural resistance are useful during the design process to prevent the occurrence of progressive collapse. Buildings subjected to continuous instances of expected/non-expected loadings due to extreme events (e.g., earthquakes, explosions, floods, hurricanes) can collapse. A lack of specific knowledge from [...] Read more.
Quantitative analyses of structural resistance are useful during the design process to prevent the occurrence of progressive collapse. Buildings subjected to continuous instances of expected/non-expected loadings due to extreme events (e.g., earthquakes, explosions, floods, hurricanes) can collapse. A lack of specific knowledge from the designer and poor maintenance can affect collapse analyses. In this paper, the probability of failure for pancake collapse with respect to bending collapse for reinforced concrete (RC) multi-storey buildings is estimated. New combinations regarding the elastic/plastic behaviour of the material under distributed loadings on beams are proposed. Numerical 2D finite element method (FEM) analyses are carried out to model these buildings. Also, simplified dynamic analyses are carried out. The outputs are plotted in terms of the probability of failure for pancake collapse as a function of column compressive strength and the number of removed columns. The results show that the presence of elastic beams can influence the pancake collapse of columns, and, for buildings composed of several elements, the elimination of few elements has little impact on their stability. Full article
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12 pages, 2384 KiB  
Article
Binding Energies and Optical Properties of Power-Exponential and Modified Gaussian Quantum Dots
by Ruba Mohammad Alauwaji, Hassen Dakhlaoui, Eman Algraphy, Fatih Ungan and Bryan M. Wong
Molecules 2024, 29(13), 3052; https://doi.org/10.3390/molecules29133052 (registering DOI) - 27 Jun 2024
Abstract
We examine the optical and electronic properties of a GaAs spherical quantum dot with a hydrogenic impurity in its center. We study two different confining potentials: (1) a modified Gaussian potential and (2) a power-exponential potential. By using the finite difference method, we [...] Read more.
We examine the optical and electronic properties of a GaAs spherical quantum dot with a hydrogenic impurity in its center. We study two different confining potentials: (1) a modified Gaussian potential and (2) a power-exponential potential. By using the finite difference method, we solve the radial Schrodinger equation for the 1s and 1p energy levels and their probability densities and subsequently compute the optical absorption coefficient (OAC) for each confining potential using Fermi’s golden rule. We discuss the role of different physical quantities influencing the behavior of the OAC, such as the structural parameters of each potential, the dipole matrix elements, and their energy separation. Our results show that modification of the structural physical parameters of each potential can enable new optoelectronic devices that can leverage inter-sub-band optical transitions. Full article
(This article belongs to the Special Issue Two-Dimensional Materials: From Synthesis to Applications)
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19 pages, 5725 KiB  
Article
Additively Manufactured Wheel Suspension System with Integrated Conductions
by Fabian Weitz, Christian Simon Debnar, Michael Frey and Frank Gauterin
Vehicles 2024, 6(3), 1051-1069; https://doi.org/10.3390/vehicles6030050 (registering DOI) - 27 Jun 2024
Abstract
Increasing urbanisation and growing environmental awareness in society require new and innovative vehicle concepts. In the present work, the design freedoms of additive manufacturing (AM) are used to develop a front-axle wheel suspension for a novel modular vehicle concept. The development of the [...] Read more.
Increasing urbanisation and growing environmental awareness in society require new and innovative vehicle concepts. In the present work, the design freedoms of additive manufacturing (AM) are used to develop a front-axle wheel suspension for a novel modular vehicle concept. The development of the suspension components is based on a new method using industry-standard load cases for the strength design of the components. To design the chassis components, the available installation space is determined, and a suitable configuration of the chassis components is defined. Furthermore, numerical methods are used to identify the component geometries that are suitable for the force flow. The optimisation setup is selected in such a way that it is possible to integrate information, energy, and material-carrying conductions into the suspension arms. High-strength light metals are used to minimise the component masses. Apertures are provided through the components for the routing of electrical conductors. The transport of fluids is realised by conductions integrated into the wishbones. The final geometries of the suspension components are then validated by a finite element analysis (FEA) of the overall suspension model. The results of the applied method are lightweight suspension components with a high degree of functional integration. This improves the vehicle package and achieves higher front-wheel clearance, increasing the possible steering angles and thus improving manoeuvrability. The saving of unsprung mass can improve handling and has a positive effect on the vehicle’s energy consumption. Furthermore, the sectional conduction integration is followed by a simplified assembly of the front-axle suspension. Full article
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18 pages, 8919 KiB  
Article
Investigation of Lateral and Longitudinal Deformation of Submarine Nuclear Power Plant Water-Intake Tunnel on Non-Uniform Soft Soil during Earthquake
by Jie Zhao, Bo Qian, Changjiang Gan, Jianshan Wang and Yanli Peng
Appl. Sci. 2024, 14(13), 5565; https://doi.org/10.3390/app14135565 - 26 Jun 2024
Viewed by 73
Abstract
The safety-grade water-intake immersed tunnel plays a vital role in the nuclear power cooling system, and its seismic safety is crucial. This paper employs the response displacement method and dynamic time-history analysis using the finite element software ANSYS to construct a beam–spring model [...] Read more.
The safety-grade water-intake immersed tunnel plays a vital role in the nuclear power cooling system, and its seismic safety is crucial. This paper employs the response displacement method and dynamic time-history analysis using the finite element software ANSYS to construct a beam–spring model and a 3D finite element model of a shield tunnel and foundation. It also develops equivalent linear dynamic constitutive and viscoelastic boundary element subprograms. This study focuses on the weak joint sections of immersed tunnels, conducting a seismic performance analysis under extreme safety earthquake conditions (SL-2). The results indicate that the joint stiffness of immersed tunnels and the increase in seismic peak values do not affect the trend of joint opening variation with longitudinal position. The change in joint opening is primarily located where the thickness of the cover layer changes abruptly or where the soil hardness is unevenly distributed. The joint opening is mainly influenced by seismic forces when considering static and dynamic superposition. When the stiffness of the joint GINA water stop exceeds a certain value, the correlation between stiffness change and joint compression–tension variation gradually weakens. This research can provide a reference for the seismic design of similar projects. Full article
(This article belongs to the Special Issue Seismic Analysis and Design of Ocean and Underground Structures)
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13 pages, 10085 KiB  
Article
Development of Low-Pressure Die-Cast Al−Zn−Mg−Cu Alloy Propellers—Part Ⅰ: Hot Tearing Simulations for Alloy Optimization
by Min-Seok Kim and Jiwon Kim
Materials 2024, 17(13), 3133; https://doi.org/10.3390/ma17133133 - 26 Jun 2024
Viewed by 103
Abstract
Recent advances in the leisure boat industry have spurred demand for improved materials for propeller manufacturing, particularly high-strength aluminum alloys. While traditional Al-Si alloys like A356 are commonly used due to their excellent castability, they have limited mechanical properties. In contrast, 7xxx series [...] Read more.
Recent advances in the leisure boat industry have spurred demand for improved materials for propeller manufacturing, particularly high-strength aluminum alloys. While traditional Al-Si alloys like A356 are commonly used due to their excellent castability, they have limited mechanical properties. In contrast, 7xxx series alloys (Al−Zn−Mg−Cu based) offer superior mechanical characteristics but present significant casting challenges, including hot-tearing susceptibility (HTS). This study investigates the optimization of 7xxx series aluminum alloys for low-pressure die-casting (LPDC) processes to enhance propeller performance and durability. Using a constrained rod-casting (CRC) method and finite element simulations, we evaluated the HTS of various alloy compositions. The results indicate that increasing Zn and Cu contents generally increase HTS, while a sufficient Mg content of 2 wt.% mitigates this effect. Two optimized quaternary Al−Zn−Mg−Cu alloys with relatively low HTS were selected for LPDC propeller production. Simulation and experimental results demonstrated the effectiveness of the proposed alloy compositions, highlighting the need for further process optimization to prevent hot tearing in high Mg and Cu content alloys. Full article
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17 pages, 12341 KiB  
Article
PMUT-Based System for Continuous Monitoring of Bolted Joints Preload
by Stefano Sanvito, Marco Passoni, Domenico Giusti, Marco Terenzi, Carlo Prelini, Monica La Mura and Alessandro Stuart Savoia
Sensors 2024, 24(13), 4150; https://doi.org/10.3390/s24134150 - 26 Jun 2024
Viewed by 89
Abstract
In this paper, we present a bolt preload monitoring system, including the system architecture and algorithms. We show how Finite Element Method (FEM) simulations aided the design and how we processed signals to achieve experimental validation. The preload is measured using a Piezoelectric [...] Read more.
In this paper, we present a bolt preload monitoring system, including the system architecture and algorithms. We show how Finite Element Method (FEM) simulations aided the design and how we processed signals to achieve experimental validation. The preload is measured using a Piezoelectric Micromachined Ultrasonic Transducer (PMUT) in pulse-echo mode, by detecting the Change in Time-of-Flight (CTOF) of the acoustic wave generated by the PMUT, between no-load and load conditions. We performed FEM simulations to analyze the wave propagation inside the bolt and understand the effect of different configurations and parameters, such as transducer bandwidth, transducer position (head/tip), presence or absence of threads, as well as the frequency of the acoustic waves. In order to couple the PMUT to the bolt, a novel assembly process involving the deposition of an elastomeric acoustic impedance matching layer was developed. We achieved, for the first time with PMUTs, an experimental measure of bolt preload from the CTOF, with a good signal-to-noise ratio. Due to its low cost and small size, this system has great potential for use in the field for continuous monitoring throughout the operative life of the bolt. Full article
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21 pages, 6340 KiB  
Article
Automated Trucks’ Impact on Pavement Fatigue Damage
by Ali Yeganeh, Bram Vandoren and Ali Pirdavani
Appl. Sci. 2024, 14(13), 5552; https://doi.org/10.3390/app14135552 (registering DOI) - 26 Jun 2024
Viewed by 101
Abstract
The automated truck’s steering system can potentially control its lateral movement (i.e., wander mode) within the lane. The controlled wander mode of automated trucks could affect the transverse loading distribution of the wheels and consequently influence pavement fatigue damage in the long term. [...] Read more.
The automated truck’s steering system can potentially control its lateral movement (i.e., wander mode) within the lane. The controlled wander mode of automated trucks could affect the transverse loading distribution of the wheels and consequently influence pavement fatigue damage in the long term. This study examines the effects of potential wander modes on pavement fatigue damage, considering the effects of lane width, market penetration rate, flexible pavement layers’ thickness, and stiffness of the materials. This study uses a finite element model to calculate the flexible pavement response. The mechanistic–empirical method is used to compute the total fatigue damage index for a specific design period, incorporating the wander mode effect. Comparing the fatigue damage indices indicates that automated trucks could either reduce the damage index value from −1.41% to −7.05% (i.e., mitigator scenario) or increase it from +11.6% to +278.57% (i.e., aggravator scenario), depending on their deployment scenarios. Moreover, the findings show that using a uniform-wander mode instead of a zero-wander mode or increasing the thickness and stiffness of the pavement layers could effectively reduce the adverse effect of automated trucks on fatigue damage and reduce the damage indices from −0.06% to −42.95%. However, their impact is considerably influenced by market penetration rate and lane width. Full article
(This article belongs to the Special Issue Advances in Intelligent Road Design and Application)
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20 pages, 12614 KiB  
Case Report
Forensic Analysis on Damage of a Cable-Stayed Bridge without Backstays Using BIM Information
by Qi Xu, Xuefei Shi, Ziqi Xu and Haiying Ma
Appl. Sci. 2024, 14(13), 5538; https://doi.org/10.3390/app14135538 - 26 Jun 2024
Viewed by 89
Abstract
Serious cracks were found in the pylon of a cable-stayed bridge without backstays. Based on forensic damage investigation, this paper uses the finite element (FE) method incorporating Building Information Modeling (BIM) to analyze the causes of cracking. The BIM model is established based [...] Read more.
Serious cracks were found in the pylon of a cable-stayed bridge without backstays. Based on forensic damage investigation, this paper uses the finite element (FE) method incorporating Building Information Modeling (BIM) to analyze the causes of cracking. The BIM model is established based on the survey of design, construction, and service information of the bridge. Then, FE analysis is conducted using BIM information. Finally, the causes of cracking in different regions of the pylon are explained in detail. The results show that the FE simulation agrees well with the inspected distribution of cracks, and the causes of cracks are closely related to the pylon construction process. The main cause of the cracks is the shrinkage difference between concrete segments of different ages. The anchorage effect of stayed cables also causes inclined cracks perpendicular to the cable direction. The combination of temperature load and concrete shrinkage results in cracks at the root of the pylon, and the reduction in cable forces exacerbates the cracking. Full article
(This article belongs to the Section Civil Engineering)
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10 pages, 2284 KiB  
Article
The Influence of Large Variations in Fluid Density and Viscosity on the Resonance Characteristics of Tuning Forks Simulated by Finite Element Method
by Feng Jiang, Dehua Chen, Xiao He, Yuyu Dai, Man Tang, Yinqiu Zhou and Mi Zhang
Appl. Sci. 2024, 14(13), 5540; https://doi.org/10.3390/app14135540 - 26 Jun 2024
Viewed by 90
Abstract
The use of tuning forks to measure fluid density and viscosity is widely employed in fields such as food, medicine, textiles, automobiles, petrochemicals, and deep drilling. The explicit analytical model based on the Euler–Bernoulli cantilever-beam theory for the relationship between tuning-fork resonance characteristics [...] Read more.
The use of tuning forks to measure fluid density and viscosity is widely employed in fields such as food, medicine, textiles, automobiles, petrochemicals, and deep drilling. The explicit analytical model based on the Euler–Bernoulli cantilever-beam theory for the relationship between tuning-fork resonance characteristics and the density and viscosity of fluid is only applicable to the situation where the fluid viscous effect is very small. In this paper, the finite element method is used to simulate the influence of large variations in fluid density and viscosity on the resonance characteristic parameters (resonant frequency and quality factor) of the tuning fork. The numerical simulation results are compared with the analytical analysis results and experimental measurement results. Then, the sensitivity of tuning-fork resonance characteristic parameters to fluid density and viscosity is studied. The results show that compared with the analytical results, the numerical simulation results have a higher degree of agreement with the experimental measurement results. The relative difference in resonant frequency is less than 2%, and the relative difference in quality factor is less than 4%. This indicates that the finite element method includes the influence of fluid viscosity on tuning-fork resonance parameters, which is more in line with the actual conditions than the analytical model. Simulating and analyzing the sensitivity of the tuning fork to fluid density and viscosity by the finite element method, it is possible to consider the situation where fluid density and viscosity vary over a large range. Compared with experimental measurements, this method has higher efficiency and can significantly save time and economic costs. This study can overcome the limitation of existing explicit analytical models, which are only applicable when the viscous effects of the fluid are very small. It enables a more accurate simulation of the coupling vibration between tuning forks and fluids, thereby providing theoretical references for further optimizing tuning-fork structural parameters to enhance the accuracy of measuring fluid characteristic parameters. Full article
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14 pages, 3865 KiB  
Article
Temperature Effect of Composite Girders with Corrugated Steel Webs Considering Local Longitudinal Stiffness of Webs
by Minghao Cai, Shizhong Liu and Fangxu Wang
Buildings 2024, 14(7), 1939; https://doi.org/10.3390/buildings14071939 - 26 Jun 2024
Viewed by 105
Abstract
The theoretical calculation formula for the temperature effect of composite box beams with corrugated steel webs and arbitrary temperature gradient distribution is derived based on the structural characteristics of such beams. This is achieved by considering the deformation coordination condition of the steel [...] Read more.
The theoretical calculation formula for the temperature effect of composite box beams with corrugated steel webs and arbitrary temperature gradient distribution is derived based on the structural characteristics of such beams. This is achieved by considering the deformation coordination condition of the steel and concrete interface, as well as taking into account the longitudinal constraint effect of the web. An analysis is conducted to compare the results obtained from a fine finite element numerical example with those from the theoretical formula. This study also investigates the height of the common flexural zone of corrugated steel web and concrete, confirming the correctness of the theoretical formula. The findings indicate that, when 10% of the height of the corrugated steel web is considered as the common flexural area, there is optimal agreement between the theoretical values and finite element values, resulting in calculated results that are more consistent with actual stress states in this type of box girder bridge. Furthermore, it is observed that the interfacial shear force and interface slip between the steel and concrete in composite beams are not uniformly distributed along their longitudinal axis. Specifically, the interfacial shear force follows a hyperbolic cosine function along this axis, reaching its maximum value at mid-span while being zero at both ends. On the other hand, the interface slip follows a hyperbolic sine function along this axis, reaching its maximum value at the beam end while being zero within the span. It should be noted that factors such as the interface slip stiffness, temperature difference, and linear expansion coefficient have a significant influence on the temperature effects in composite beams. In addition to these factors, a reasonable arrangement of shear nails on steel plates has been identified as an effective method for mitigating adverse effects. Full article
(This article belongs to the Section Building Structures)
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18 pages, 1226 KiB  
Article
Parameter Sensitivity Analysis for Machining Operation of Autofrettaged Cylinder using Taguchi Method
by Murat Oymak, Halil Yıldırım, Mustafa Yıldız, Burak Özcan, Yasin Çelebi, Muhammet Abdullah Enes Çelebi and Veli Çelik
Appl. Sci. 2024, 14(13), 5523; https://doi.org/10.3390/app14135523 - 25 Jun 2024
Viewed by 164
Abstract
This study investigates the impact of material parameters such as yield strength (Sy), Young’s modulus (E), and tangent modulus (T) on the safety factor (SF) of autofrettaged cylinders under 400 MPa working pressure, considering [...] Read more.
This study investigates the impact of material parameters such as yield strength (Sy), Young’s modulus (E), and tangent modulus (T) on the safety factor (SF) of autofrettaged cylinders under 400 MPa working pressure, considering the three scenarios: no machining, internal machining, and external machining. Finite element (FE) simulations were conducted based on the Taguchi experimental design and converted into signal-to-noise (S/N) ratios to determine the optimal settings. ANOVA was utilized to evaluate the significance and percentage contributions of each factor. The analysis indicated that Sy is the most influential parameter on SF, contributing approximately 98.20% across all scenarios, including no machining, internal machining, and external machining. The contributions of E and T were minimal, but T had a slightly greater effect than E. The analytical validation of the FE model showed good agreement, with a maximum deviation of 4.37% for no machining, 4.75% for internal machining, and 5.20% for external machining. Regression analysis further confirmed the high prediction capability of the model, validated using AISI 4340 steel. The study concludes that internal machining results in higher residual stress loss compared to external machining. Overall, the analytical method tends to provide lower SF values than the numerical method, highlighting its conservative nature. Full article
(This article belongs to the Special Issue Structural Mechanics: Theory, Method and Applications)
13 pages, 1916 KiB  
Article
Prediction of Placental Abruption of Pregnant Women Drivers with Various Collision Velocities, Seatbelt Positions and Placental Positions—Analysis with Novel Pregnant Occupant Model
by Tomohiro Izumiyama, Atsuno Tsuji, Katsunori Tanaka, Yumiko Tateoka, Ryusuke Asahi, Hiroshi Hamano, Masahito Hitosugi and Shigeru Sugimoto
Int. J. Environ. Res. Public Health 2024, 21(7), 827; https://doi.org/10.3390/ijerph21070827 (registering DOI) - 25 Jun 2024
Viewed by 166
Abstract
The aims of this study were as follows: the (a) creation of a pregnant occupant finite element model based on pregnant uterine data from sonography, (b) development of the evaluation method for placental abruption using this model and (c) analysis of the effects [...] Read more.
The aims of this study were as follows: the (a) creation of a pregnant occupant finite element model based on pregnant uterine data from sonography, (b) development of the evaluation method for placental abruption using this model and (c) analysis of the effects of three factors (collision speed, seatbelt position and placental position) on the severity of placental abruption in simulations of vehicle collisions. The 30-week pregnant occupant model was developed with the uterine model including the placenta, uterine–placental interface, fetus, amniotic fluid and surrounding ligaments. A method for evaluating the severity of placental abruption on this pregnant model was established, and the effects of these factors on the severity of the injury were analyzed. As a result, a higher risk of placental abruption was observed in high collision speeds, seatbelt position over the abdomen and anterior-fundal placenta. Lower collision speeds and seatbelt position on the iliac wings prevented severe placental abruption regardless of placental positions. These results suggested that safe driving and keeping seatbelt position on the iliac wings were essential to decrease the severity of this injury. From the analysis of the mechanism for placental abruption, the following hypothesis was proposed: a shear at adhesive sites between the uterus and placenta due to direct seatbelt loading to the uterus. Full article
13 pages, 4221 KiB  
Article
Design, Analysis, and Comparison of Electric Vehicle Drive Motor Rotors Using Injection-Molded Carbon-Fiber-Reinforced Plastics
by Huai Cong Liu, Jang Soo Park and Il Hwan An
World Electr. Veh. J. 2024, 15(7), 283; https://doi.org/10.3390/wevj15070283 - 25 Jun 2024
Viewed by 636
Abstract
Due to their excellent mechanical strength, corrosion resistance, and ease of processing, carbon fiber and carbon-fiber-reinforced plastics are finding wide application in diverse fields, including aerospace, industry, and automobiles. This research explores the feasibility of integrating carbon fiber solutions into the rotors of [...] Read more.
Due to their excellent mechanical strength, corrosion resistance, and ease of processing, carbon fiber and carbon-fiber-reinforced plastics are finding wide application in diverse fields, including aerospace, industry, and automobiles. This research explores the feasibility of integrating carbon fiber solutions into the rotors of 85-kilowatt electric vehicle interior permanent magnet synchronous motors. Two novel configurations are proposed: a carbon fiber wire-wound rotor and a carbon fiber injection-molded rotor. A finite element analysis compares the performance of these models against a basic designed rotor, considering factors like no-load back electromotive force, no-load voltage harmonics, cogging torque, load torque, torque ripple, efficiency, and manufacturing cost. Additionally, a comprehensive analysis of system efficiency and energy loss based on hypothetical electric vehicle parameters is presented. Finally, mechanical strength simulations assess the feasibility of the proposed carbon fiber composite rotor designs. Full article
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22 pages, 3229 KiB  
Article
Enhancing the Forming Accuracy of CFRP through a Global Compensation Method by Introducing an Optimal Profile
by Yongming Zhang, Luling An and Cong Zhao
Polymers 2024, 16(13), 1792; https://doi.org/10.3390/polym16131792 - 25 Jun 2024
Viewed by 129
Abstract
Irreversible curing distortion represents a significant limiting factor in the application of high-performance composite structures. Curing distortion is the deviation of a component’s profile from the theoretical profile after demolding. Introducing the optimal compensation profile into the traditional compensation algorithm represents an effective [...] Read more.
Irreversible curing distortion represents a significant limiting factor in the application of high-performance composite structures. Curing distortion is the deviation of a component’s profile from the theoretical profile after demolding. Introducing the optimal compensation profile into the traditional compensation algorithm represents an effective method to enhance CFRPs’ forming accuracy. For this method, it is necessary to obtain the optimal compensating profile by establishing the coordinate model of the curing process parameter and mold profile compensation. The coordinated control model consists of four parameters: the mean value (Dav), root mean square value (Dmsr), minimum (Dmin), and maximum (Dmax) of curing distortion. Two sizes of composite structural parts are manufactured using the global compensation method. We investigate the influence mechanisms of heating, holding, and cooling times on curing distortion and residual stresses and develop a multi-field coupled finite element model. Strong agreement between the numerical and experimental findings serves as evidence for the effectiveness of the numerical model. The middle layer of the fabricated parts exhibit a reduction in residual stresses as the heating and holding times increase, while an opposite trend is noted with an increase in cooling time. Refining the design of curing process parameters can yield the minimum value of curing deformation within the specified resin system interval. Comparisons indicate that the distortion of the composite wall panel structure is reduced by 86.2% through the use of the global compensation method, demonstrating the validity of this approach for composite structures. Full article
(This article belongs to the Section Polymer Processing and Engineering)
17 pages, 1564 KiB  
Article
Mixing and Thermal Transport Behavior in a Pin or Non-Pin Extruder Equipped with a Field Synergy Elongation Screw
by Yancai Sun, Shilong Wang, Shizheng Huang, Wei Pan, Yan He and Ranran Jian
Polymers 2024, 16(13), 1793; https://doi.org/10.3390/polym16131793 - 25 Jun 2024
Viewed by 136
Abstract
The ductile forming process of a polymer in a standard screw extruder and pin-barrel extruder, equipped with or without a field synergy elongation screw, was investigated by the finite element method. In order to assess the mixing and heat transfer capabilities of screws, [...] Read more.
The ductile forming process of a polymer in a standard screw extruder and pin-barrel extruder, equipped with or without a field synergy elongation screw, was investigated by the finite element method. In order to assess the mixing and heat transfer capabilities of screws, characteristic parameters such as the mixing efficiency, segregation scale, and temperature distribution of different structures were analyzed and compared. The results indicated that the flow pattern of the polymer melt in the extruder was significantly influenced by the screw structure and was improved by the newly designed field synergy screw configuration, which brought a desirable elongational flow to enhance the radial convection. This was attributed to the unique radial wedge-shaped repeated convergence region of the field synergy elongation screw, increasing the synergistic effect between the velocity field, velocity gradient field, and temperature gradient field and thus improving the heat transfer and mixing efficiency. After adding barrel pins, the flow was forced to split, resulting in a more significant stretching effect on the melt. The field synergy effect in the pin mixed region was strengthened, which further increased the heat and mass transfer efficiency of the screw. However, increasing barrel pins could also lead to undesired temperature fluctuation and flow resistance, which have a negative impact on the melt uniformity. This study offers an important reference for optimizing screw structure to obtain strong mixing and heat transfer performances. Full article
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