Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Finite Element Modelling”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3

Efficient Computation of Info-Gap Robustness for Finite Element Models

A recent research effort at LANL proposed info-gap decision theory as a framework by which to measure the predictive maturity of numerical models. Info-gap theory explores the trade-offs between accuracy, that is, the extent to which predictions reproduce the physical measurements, and robustness, that is, the extent to which predictions are insensitive to modeling assumptions. Both accuracy and robustness are necessary to demonstrate predictive maturity. However, conducting an info-gap analysis can present a formidable challenge, from the standpoint of the required computational resources. This is because a robustness function requires the resolution of multiple optimization problems. This report offers an alternative, adjoint methodology to assess the info-gap robustness of Ax = b-like numerical models solved for a solution x. Two situations that can arise in structural analysis and design are briefly described and contextualized within the info-gap decision theory framework. The treatments of the info-gap problems, using the adjoint methodology are outlined in detail, and the latter problem is solved for four separate finite element models. As compared to statistical sampling, the proposed methodology offers highly accurate approximations of info-gap robustness functions for the finite element models considered in the report, at a small fraction of the computational cost. It is noted that this report considers only linear systems; a natural follow-on study would extend the methodologies described herein to include nonlinear systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Finite element modeling of nanoscale-enabled microinductors for power electronics

Here, this paper focuses on the finite element modeling of toroidal microinductors, employing first-of-its-kind nanocomposite magnetic core material and superparamagnetic iron nanoparticles covalently cross-linked in an epoxy network. Energy loss mechanisms in existing inductor core materials are covered as well as discussions on how this novel core material eliminates them providing a path toward realizing these low form factor devices. Designs for both a 2 μH output and a 500 nH input microinductor are created via the model for a high-performance buck converter. Both modeled inductors have 50 wire turns, less than 1 cm 3 form factors, less than 1 Ω AC resistance, and quality factors, Q’s, of 27 at 1 MHz. In addition, the output microinductor is calculated to have an average output power of 7 W and a power density of 3.9 kW/in 3 by modeling with the 1st generation iron nanocomposite core material.

36 MATERIALS SCIENCE↗

Development of an Advanced Finite Element Model and Parametric Study to Evaluate Cement Sheath Barrier

Cement failure is known as one of the major causes for loss of well control events. Cement design is considered as one of the top technological knowledge gaps in high-pressure high-temperature oil and gas exploration. The primary objective of this paper is to perform a parametric analysis and identify critical parameters affecting the mechanical integrity of the set cement sheath. To achieve the objective, three-dimensional finite element models consisting of concentric casings and annular cement sheath were created. The finite element model was validated by analytical calculations. Performance of cement sheath was assessed by analyzing radial, hoop, and maximum shear stresses at different loading conditions. A parametric study was conducted by individually varying influencing factors such as cement material properties, sheath dimensions, and wellbore pressure loads. Values of all parameters were normalized and represented on the same plot against mechanical stresses. Such response curves can be used to estimate whether cement will structurally fail because of various operational loads or material aging. The plot can also be utilized to rank various factors in terms of influence on cement’s performance. Sensitivity response reveals that wellbore pressure, cement material properties, and annulus pressure are major parameters influencing mechanical stresses in neat class G cement. The order of importance depends on the type of stress. Results indicate interfacial bond failure and radial cracking to be the more likely modes of failure for class G cement. Cement response curves can help design engineers and regulators alike in quickly evaluating short-term or long-term fitness-for-service of cement sheath from the perspective of structural integrity. Industry standards and guidelines can be improved by adding performance curves for standard cement recipes.

Energy & Fuels↗

High-temperature compressive creep tests of U 3 Si 2 with spark plasma sintering: Experiments and finite element modeling

This paper reports a systematic high-temperature creep behavior of dense U 3 Si 2 pellets using a spark plasma sintering (SPS) apparatus at elevated temperatures and pressures under vacuum conditions. The stress exponent was subsequently derived to be 3.21 at 1173 K and 2.17 at 1223 K, respectively, indicating a grain boundary sliding creep mechanism. The creep activation energy was determined to be 203.6 ± 19.0 kJ/mol, which agrees well with the literature. Finite element modeling was performed using the creep parameters fitted from the strain-time plot. Additionally, the results suggest an excellent match with the experimental data, confirming the validity of the experiments. Microstructure characterizations indicate that the main phase of the specimens after creep tests remains to be U 3 Si 2 , with a 4 μm thick layer of nano-sized particles induced from the diffusion between U 3 Si 2 and alumina disc used to avoid electric current passing through the sample. The successful conduct of creep experiments demonstrates the great potential of SPS to perform high-temperature mechanical testing of nuclear fuels under vacuum conditions. The subsequent finite element modeling exhibits excellent capabilities for accurately predicting material performance in the creep tests and provides a practical tool in evaluating nuclear fuels’ performance for a much-extended time scale.

36 MATERIALS SCIENCE↗

CoCrMo cellular structures made by Electron Beam Melting studied by local tomography and finite element modelling

The work focuses on the structural and mechanical characterization of Co-Cr-Mo cellular samples with cubic pore structure made by Electron Beam Melting (EBM). X-ray tomography was used to characterize the architecture of the sample. High resolution images were also obtained thanks to local tomography in which the specimen is placed close to the X-ray source. These images enabled to observe some defects due to the fabrication process: small pores in the solid phase, partially melted particles attached to the surface. Then, in situ compression tests were performed in the tomograph. The images of the deformed sample show a progressive buckling of the vertical struts leading to final fracture. The deformation initiated where the defects were present in the strut i.e. in regions with reduced local thickness. The finite element modelling confirmed the high stress concentrations of these weak points leading to the fracture of the sample. - Highlights: • CoCrMo samples fabricated by Electron Beam Melting (EBM) process are considered. • X-ray Computed Tomography is used to observe the structure of the sample. • The mechanical properties are tested thanks to an in situ test in the tomograph. • A finite element model is developed to model the mechanical behaviour.

36 MATERIALS SCIENCE↗

Permittivity effects of particle agglomeration in ferroelectric ceramic-epoxy composites using finite element modeling

Here, the size dependence of the dielectric constants of barium titanate or other ferroelectric particles can be explored by embedding particles into an epoxy matrix whose dielectric constant can be measured directly. However, to extract the particle dielectric constant requires a model of the composite medium. We compare a finite element model for various volume fractions and particle arrangements to several effective medium approximations, which do not consider particle arrangement explicitly. For a fixed number of particles, the composite dielectric constant increases with the degree of agglomeration, and we relate this increase to the number of regions of enhanced electric field along the applied field between particles in an agglomerate. Additionally, even for dispersed particles, we find that the composite method of assessing the particle dielectric constant may not be effective if the particle dielectric constant is too high compared to the background medium dielectric constant.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Finite Element Modeling of Electrochemical Polishing of Niobium in Hydrofluoric-Sulfuric Acid Electrolyte

Niobium (Nb) used in superconducting radio-frequency cavities requires smooth surface to achieve optimal performance. In this work, a finite element model that coupled electrochemistry, heat transfer, and fluid dynamics was developed to investigate the electrochemical polishing mechanisms of Nb, using experimentally measured polarization results of coupon samples as validations. The current and potential distribution, oxide growth kinetics of Nb in a complex cavity geometry was investigated as a function of temperature and coolant flow. A low temperature coolant with intermediate flow rate was found to reduce surface current and ensure oxide uniformity. These results could shed light on the design of future particle accelerators.

SRF accelerator cavity↗

Finite Element Modeling of the Fiber-Matrix Interface in Polymer Composites

Polymer composites are used in numerous industries due to their high specific strength and high specific stiffness. Composites have markedly different properties than both the reinforcement and the matrix. Of the several factors that govern the final properties of the composite, the interface is an important factor that influences the stress transfer between the fiber and matrix. The present study is an effort to characterize and model the fiber-matrix interface in polymer matrix composites. Finite element models were developed to study the interfacial behavior during pull-out of a single fiber in continuous fiber-reinforced polymer composites. A three-dimensional (3D) unit-cell cohesive damage model (CDM) for the fiber/matrix interface debonding was employed to investigate the effect of interface/sizing coverage on the fiber. Furthermore, a two-dimensional (2D) axisymmetric model was used to (a) analyze the sensitivity of interface stiffness, interface strength, friction coefficient, and fiber length via a parametric study; and (b) study the shear stress distribution across the fiber-interface-matrix zone. It was determined that the force required to debond a single fiber from the matrix is three times higher if there is adequate distribution of the sizing on the fiber. The parametric study indicated that cohesive strength was the most influential factor in debonding. Moreover, the stress distribution model showed the debonding mechanism of the interface. It was observed that the interface debonded first from the matrix and remained in contact with the fiber even when the fiber was completely pulled out.

36 MATERIALS SCIENCE↗

Improved detection of rough defects for ultrasonic NDE inspections based on finite element modeling of elastic wave scattering

Defects which posses rough surfaces greatly affect ultrasonic wave scattering behaviour, often reducing the magnitude of reflected signals. Ultrasonic inspections rely upon this response for detecting and sizing flaws. For safety critical components reliable characterisation is crucial. Therefore, providing an accurate means to predict reductions in signal amplitude is essential. An extension of Kirchhoff theory has formed the basis for the UK power industry inspection justifications. However, it is widely recognised that these predictions are pessimistic owing to analytical approximations. A numerical full field modelling approach does not fall victim to such limitations. Here, a Finite Element model is used to aid in setting a non-conservative reporting threshold during the inspection of a large pressure vessel forging that might contain embedded rough defects. The ultrasonic response from multiple rough surfaces defined by the same statistical class is calculated for normal incident compression waves. The approach is validated by comparing coherent scattering with predictions made by Kirchhoff theory. At lower levels of roughness excellent agreement is observed, whilst higher values confirm the pessimism of Kirchhoff theory. Furthermore, the mean amplitude in the specular direction is calculated. This represents the information obtained during an inspection, indicating that reductions due to increasing roughness are significantly less than the coherent component currently being used.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

3-D Thermal-Electric Finite Element Model of a Nb 3 Sn Coil During a Quench

High field superconducting magnets for particle accelerators often exhibit premature quenches. Once a normal zone is generated within the conductor, the quench may propagate causing temperature and resistive voltage rise along the coil. The resulting thermal gradients can potentially cause new peak stresses that might exceed the tolerable limits, degrading the conductor. The computation of the strain state in the coils during quench then becomes of paramount importance for magnet design, and requires a complete three-dimensional (3-D) analysis of quench phenomena. The objective of this paper is to present the first multiphysics modeling activities towards a new full 3-D methodology for the analysis of magnet mechanics during quench. As a first step, a 3-D thermal-electric finite element model of a Nb 3 Sn superconducting coil is developed and explained here. The model uses direct coupled-field elements to solve the system of thermal and electrical equations. A solving algorithm has also been implemented in order to investigate the physics behind quench transients. The output from this model, built in ANSYS APDL, can be easily coupled in a later stage to a mechanical model in order to estimate the strain state in the coil windings. In conclusion, a very good agreement has been observed between the numerical results and experimental tests performed in individual superconducting cables and real superconducting magnets.

43 PARTICLE ACCELERATORS↗

Influence of thin-film metallic glass coating on fatigue behavior of bulk metallic glass: Experiments and finite element modeling

In this paper, a coating of the Zr-based thin-film metallic glass (TFMG) was deposited on the Zr 50 Cu 30 Al 10 Ni 10 bulk metallic glass (BMG) to investigate shear-band evolution under four-point-bend fatigue testing. The fatigue endurance-limit of the TFMG-coated samples is ~ 33% higher than that of the BMG. The results of finite-element modeling (FEM) revealed a delay in the shear-band nucleation and propagation in TFMG-coated samples under applied cyclic-loading. The FEM study of spherical indentation showed that the redistribution of stress by the TFMG coating prevents localized shear-banding in the BMG substrate. Finally, the enhanced fatigue characteristics of the BMG substrates can be attributed to the TFMG coatings retarding shear-band initiation at defects on the surface of the BMG.

36 MATERIALS SCIENCE↗

Parallel projection—An improved return mapping algorithm for finite element modeling of shape memory alloys

Here, we present a novel finite element analysis of inelastic structures containing Shape Memory Alloys (SMAs). Phenomenological constitutive models for SMAs lead to material nonlinearities, that require substantial computational effort to resolve. Finite element analysis methods, which rely on Gauss quadrature integration schemes, must solve two sets of coupled differential equations: one at the global level and the other at the local, i.e. Gauss point level. In contrast to the conventional return mapping algorithm, which solves these two sets of coupled differential equations separately using a nested Newton procedure, we propose a scheme to solve the local and global differential equations simultaneously. In the process we also derive closed-form expressions used to update the internal/constitutive state variables, and unify the popular closest-point and cutting plane methods with our formulas. Numerical testing indicates that our method allows for larger thermomechanical loading steps and provides increased computational efficiency, over the standard return mapping algorithm.

42 ENGINEERING↗

SurFE-XD (Surface curvature-driven Finite Elements model for Diffusion under eXtreme conditions)

SurFE-XD is a mesoscale finite element framework to model surface diffusion under mutliphysics environments. The code uses legacy C++ library dolphin wrapped with python in a FEniCS driven unified form language and just-in-time (JIT) compilation setting. The purpose of the release is to attract wide-ranging usage of the code along with publication supplementation to support reproducibility of scientific data. SurFE-XD has been originally conceived under the LDRD-DR funding for “High-Gradient (C-BAND) Breakdown tolerant accelerator materials project. Currently SrFE-XD support electrostatics and Thermo-elasticity driven surface diffusion kernels. Releasing the code will also enable to include contributions from other physical regimes e.g., plasticity and electrodynamics etc as well portability to GPU-based platforms.

Bagchi, Soumendu↗

Element-based concrete design with three-dimensional finite element models

A shell element based design of a typical shear wall using analytical results from a three-dimensional finite element model subjected to a combination of vertical and lateral loads is evaluated. The axial and flexural force resultants from each element for every load combination are used to calculate the required reinforcing for each element. Strength for axial loads (P) and out-of-plane flexure (M) in structural walls is determined according to the same P-M interaction procedures used for columns. After each element has been evaluated, a required reinforcing map for each face of each element in the wall is presented along with a constructible reinforcement pattern enveloping the required reinforcing. In order to determine whether the element-based approach meets the requirements of the section cut approach to design, which is typically employed in manual calculations, the total in-plane moment (M) and total vertical axial force (P) across the entire length of the wall is calculated and the P-M points are plotted on an in-plane P-M interaction diagram. It is concluded that element-based design for a structural wall ensures that reinforcement is provided where required by the three-dimensional finite element analysis while still providing sufficient reinforcing to satisfy the section cut approach to design. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Validation Assessment of a Glass-to-Metal Seal Finite-Element Model

Sealing glasses are ubiquitous in high pressure and temperature engineering applications, such as hermetic feed-through electrical connectors. A common connector technology are glass-to-metal seals where a metal shell compresses a sealing glass to create a hermetic seal. Though finite-element analysis has been used to understand and design glass-to-metal seals for many years, there has been little validation of these models. An indentation technique was employed to measure the residual stress on the surface of a simple glass-to-metal seal. Recently developed rate- dependent material models of both Schott 8061 and 304L VAR stainless steel have been applied to a finite-element model of the simple glass-to-metal seal. Model predictions of residual stress based on the evolution of material models are shown. These model predictions are compared to measured data. Validity of the finite- element predictions is discussed. It will be shown that the finite-element model of the glass-to-metal seal accurately predicts the mean residual stress in the glass near the glass-to-metal interface and is valid for this quantity of interest.

42 ENGINEERING↗

Predicting Pit Stability On Additively Manufactured SS316 Via Finite Element Modeling [Slides]

Pit growth and repassivation are complex, with many interconnecting geometric and environmental parameters to consider. Experimentally, it is difficult to isolate these individual parameters to study their effect on the stability of pits. To enable these studies, a finite element modeling approach has been developed to allow systematic testing of parameters that impact a pit’s stability. The specific parameters studied were the cathode diameter, the pit diameter and shape, and the water layer thickness. Hemispherical and rectangular-based pits were studied to determine the impact of the overall pit shape. Pit stability results were compared with mathematical calculations based on the Maximum Pit Model, for both 50% saturation and 100% saturated salt film coverage. Further studies expanded the range of pit geometry to those relevant to additively manufactured surfaces.

36 MATERIALS SCIENCE↗

A discrete-continuum coupled finite element modelling approach for fibre reinforced concrete

Highlights: • An easy-to-implement but effective meso-scale modelling approach is developed for FRC. • It is capable of simulating and interpreting all main failure mechanisms in FRC. • It is critically validated by experiments with single or multiple random fibres under various loading conditions. • It can be used to optimise key design factors of FRC at meso/material scale by parametric studies. - Abstract: Fibre reinforced concrete (FRC) exhibits complicated failure modes such as fibre breakage, mortar cracking, crushing and spalling, fibre-mortar interfacial debonding, depending on many material properties, geometric dimensions, boundary and loading conditions. Most existing numerical models are unable to reproduce these failure modes that may occur simultaneously or sequentially in a specimen, mainly due to difficulties in generating finite element meshes with a large number of randomly-oriented fibres. Herein we develop a discrete-continuum coupled finite element modelling approach for FRC materials capable of effectively simulating all the major failure modes. The continuum damaged plasticity model is used to simulate damage and fracture behaviour of the mortar, while debonding of fibre-mortar interfaces is modelled by nonlinear cohesive interfacial elements. Unique techniques are devised to generate conforming meshes between fibres and the surrounding mortar so that the randomly-oriented fibres are easily modelled. The modelling approach is validated by simulating single fibre pullout tests with different inclination angles, notched and non-notched direct tensile tests and three-point bending beam tests with randomly-distributed multiple fibres.

36 MATERIALS SCIENCE↗