Finite Element Analysis and Optimization of High Speed E-mobility Seal

The aim of this paper is to model the steady-state condition of a rotary shaft seal (RSS) system. For this, an iterative thermal-mechanical algorithm was developed based on incremental finite element analyzes. The behavior of the seal’s rubber material was taken into account by a large-strain viscoelastic, so called generalized Maxwell model, based on Dynamic Mechanical Thermal Analyses (DMTA) and tensile measurements. The pre-loaded garter spring was modelled with a bilinear material model and the shaft was assumed to be linear elastic. The density, coefficient of thermal expansion and the thermal conductance of the materials were taken into consideration during simulation. The friction between the rotary shaft seal and the shaft was simplified and modelled as a constant parameter. The iterative algorithm was evaluated at two different times, right after assembly and 1 h after assembly, so that rubber material’s stress relaxation effects are also incorporated. The results show good correlation with the literature data, which state that the permissible temperature for NBR70 (nitrile butadiene rubber) material contacting with ~80 mm shaft diameter, rotating at 2600/min is 100°C. The results show 107°C and 104°C for the two iterations. The effect of friction induced temperature, changes the width of the contact area between the seal and the shaft, and significantly reduces the contact pressure.

There has been a growing demand for nonlinear model updating procedures in the structural dynamics community as advanced vehicles have started to incorporate nonlinearity into their designs. Finite element (FE) model updating is difficult for a nonlinear structure for several reasons: there may be many unknown parameters in the FE model so that multiple solutions may exist, and it is very expensive to compute the structure’s nonlinear normal modes from a full FE model that are an excellent metric to use for nonlinear updating. A recent work showed that some of these challenges can be overcome by updating a nonlinear reduced order model (ROM) rather than the full FE model. The updated ROM can be used to compute response statistics, stresses and ultimately life of the structure. However, one drawback of this approach is that one does not gain physical insight into which parameters in the FE model were in error, and so it is difficult to transfer the lessons learned to future FE models. This work explores the feasibility of updating a FE model to correlate with a ROM with a set of known parameters. The target ROM parameters consist of the linear stiffness and the nonlinear stiffness coefficients which have been identified previously by updating the ROM to correlate with experimental measurements. In this process an optimization routine is setup in which the free parameters are those of the FE model, such as boundary stiffness springs, imperfections, pre-stress, etc. The optimization procedure is wrapped around a ROM creation algorithm that iteratively tunes the FE parameters, creates a ROM, and evaluates the ROM parameters with respect to the target ROM in order to minimize the objective function. This work will demonstrate the procedure on a numerical example of a curved beam in order to verify its effectiveness on the nonlinear model updating.

Objective To explore the establishment of 3D thoracic model by finite element methods, and study the mechanical mechanism of minimally invasive surgery for correcting the chest wall deformity, and provide personalized surgery solution in the future. Methods According to admission and exclusion criteria, we selected 10 cases of pectus carinatum that received chest CT scan. The finite element model of pectus carinatum was established and analyzed by Mimics, ABAQUS, etc. The validity of finite element method for chest wall was verified by comparing the sternal displacement between the simulated values and actual values with the same force. Results The 3D finite element model of pectus carinatum was successfully established and analyzed. The stress distribution of the 10 cases in the posterior ribs was mainly in the 1-6 ribs on both sides, mostly concentrated in the 4th to 6th ribs, and the stress was symmetrical on both sides. Statistical analysis showed that the displacement value of the sternum was correlated, and the validity of the model was verified. Conclusion Mimics, ABAQUS and other finite element modeling and analysis software can effectively establish the thoracic 3D finite element model and mechanical analysis, which can help the further development of personalized minimally invasive surgery for correcting chest wall deformities. Key words: Pectus carinatum; Chest wall deformity; Finite element analysis

PurposeWe aimed to determine if finite element analysis (FEA) provides useful thresholds for bone biopsy practice patterns.MethodsThe femoral head compression test was performed on rabbit femurs, using FEA to identify the part of the bone that preferentially fractures (n=15/group). Four types of rectangular biopsy holes were made using finite element (FE) models. These models were divided into control (no defect), defect 1 (10% width), defect 2 (20% width), defect 3 (30% width), and defect 4 (40% width) groups (n=15 each). Three types of rectangular biopsy holes (defect A, 27% length; defect B, 40% length; defect C, 53% length) were also made using FE models (n=15 each). The load to failure was then predicted using FEA.ResultsAlmost all femurs with no defect were fractured at the femoral shaft in both the femoral head compression test and FEA. The experimental load to failure in intact femurs was predicted well by the FE models (R2=0.74, p<0.001). There was also a strong linear correlation of stiffness between compression test in femurs with no defect and the FEA (R2=0.68, p<0.001). Therefore, the femoral shaft was targeted for FEA. The median predicted loads by FEA were significantly higher for defect 1 than for the other types when testing the widths of the rectangular defects, but there were no significant differences among the three types when testing for defect length.ConclusionThe FEA results correlated well with those of the femoral head compression test. A width <10% of the circumference length in bone biopsy holes helps minimize bone strength reduction using FEA. It may be useful for orthopedic doctors to perform FEA to avoid pathological fractures after bone tumor biopsy.

The production of energy for traction in classical vehicles is performed by petrol or oil combustion. The consequence is green gas production. Paper deals with different power trains of electric hybrid and electric vehicles. Electric hybrid vehicles diminish the fuel consumption by giving to the internal combustion engine (ICE) better working conditions with respect to ICE revolutions and demanded power. The kinetic braking energy recovery is an important feature too. Electric vehicles are usually called “green vehicles”. It is true that they do not produce green gas on places where they are driving but it is also true that their traction energy has to be produced with another energy technology used in electric plants. The efficiency of the vehicle powertrain is important. The energy for transportation by vehicles in the world is great. Therefore it is very important what energy production technology for this traction purposes will be used.

Modal analysis is an approach to determine the dynamic behavior of a structure through numerical analysis or experimental approach. Nowadays, numerical analysis has been preferred by most researchers and engineers compared to experimental analysis to analyze the structure due to expenditure and time consuming factors of the research. Recently, numerical analysis is done computationally or well known as Finite Element Analysis (FEA) by using finite element (FE) model to replicate the real test structure. Instead of advantage of FE analysis, the trustworthiness of FE model has been questioned since simplification has been made during design stage for complex structure and inaccurate of geometry input of the model. Hence, this paper is carried out to reduce the discrepancies between numerical prediction results with measured test data on FE model of exhaust structure by implementing FE model updating using SOL200 algorithm. Initially, the FE model is running on normal mode analysis SOL103 to extract the modal parameters such as natural frequency and mode shape. Then, the numerical pre-diction result has been correlated and validated with measured test data obtained through Experimental Modal Analysis (EMA). Due to disagreement between numerical result and experimental data in correlation process, the FE model has been updated using SOL200 algorithm. The percentage error between numerical prediction result and measured test data is minimized from 5.67 to 3.23% after been updated. It’s shown the capability SOL200 algorithm in preparing the reliable FE model before been used for further analysis such as structural dynamic modification.KeywordsDynamic studyJoints strategyFinite element analysisExperimental modal analysisFE model updating

The present study aimed to identify the optimal design of the unicompartmental femoral component through parameter analysis and stability evaluation. A finite element (FE) analysis was applied to analyse and adjust the parameter combinations of the anterior tilt angle of the posterior condyle resection surface, the position of the peg, the length of the pegand the inclination angle of the peg, resulting in 10 different FE models. Setting three knee flexion angles of 8.4° (maximum load state during walking), 40° (maximum load state during stair climbing)and 90° (maximum load state during squatting exercise), quantitatively analysing the micromotion values of the bone-prosthesis interfaceand defining a weighted scoring formula to evaluate the stability of different FE models. The validity of the FE analysis was verified using the Digital Image Correlation (DIC) device. The errors between the FE analysis and the DIC test at three flexion angles were 5.6%, 1.7%and 11.1%. The 10 different femoral component design models were measured separately. The FE analysis demonstrated that the design with a 0° anterior tilt angle of the posterior condyle resection surface, both pegs placed on the distal resection surface, lengthened 5 mm pegsand a 10° peg inclination angle provided the best stability. The current study proposed a method for evaluating the stability of the femoral component design. The optimal intersurface stability design of the unicompartmental femoral component was achieved with two pegs placed on the distal resection surface, a 5-mm peg length incrementand a 10° peg inclination. These results might provide a reference for the selection of unicompartmental femoral components in clinical practice and therefore improve the survival rate of future unicompartmental knee arthroplasty. Level III.

The Biomechanics of a Validated Finite Element Model of Stress Shielding in a Novel Hybrid Total Knee Replacement

Typically, axial flux permanent magnet machines require 3-dimensional (3D) finite element analysis, increasing the amount of time required to complete a machine design. To overcome the drawback of 3D finite element analysis, several authors have proposed 2-dimensional (2D) finite element (FE) modeling and analysis techniques. This paper expands upon previous work, investigating quasi-boundary conditions to address end-effects and expands upon existing knowledge of discretizing the 3D problem into multiple 2D models for axial flux permanent magnet (AFPM) machines. The results of 2D finite element method are verified by a prototype which has single rotor, dual stator (SRDS) configuration. The results presented in this paper reaffirm that the less conventional SRDS AFPM can be effectively modeled in 2D, and that quasi-boundary condition can offer increased model accuracy, relative to conventional 2D FE modeling of AFPM machines.

This study investigates the feasibility of an alternative structural health monitoring (SHM) technique for an existing, post-tensioned, prestressed concrete bridge in Niigata, Japan. Currently, a static SHM system is in place to detect the progress of damages within the bridge. However, the existing system cannot properly monitor the structural health of the bridge including the periodic vibration, which is one of the damage-sensitive features of interest. Therefore, to effectively detect the real-time performances of the bridge, a three-dimensional (3D) Finite Element (FE) model was developed as a reference and verified using on-site load-deflection test results. After validating the reference FE model, different damage scenarios, such as degradation of concrete, corrosion & rupture of steel tendons and missing tendons, were incorporated in the FE models. Based on non-linear structural and Eigenvalue analyses, natural frequencies and mode shapes of the bridge remain constant even after careful consideration of all types of damages in the FE model. However, vertical displacements are observed to increase for the damage scenarios. Although the effect of tendon rupture and corrosion showed negligible influences on the vertical displacement, the deterioration of the concrete largely influenced the vertical displacement. Additionally, crack widths were found to vary with damage types. Brifely, this study recommends some effective indicators to monitor the structural conditions of the bridge using FE analysis (FEA).

The vibrational effect is one of the primary considerations during construction due to the ambient excitation from the surrounding environment. Thus, it is necessary to find the most dependable Finite Element (FE) model for the actual structure to improve its quality and life span on site. In this context, the study included a 3-story building model that was analyzed using finite element analysis to determine its dynamic properties such as natural frequency and mode shape to avoid the resonance effect. It is due to the importance of obtaining a reliable and accurate model by verifying with the results of the Operational Modal Analysis (OMA). In general, the goal of this study is to update the FE model so that it is close to the actual scaled model based on the previous OMA study. As a result, an initial linear FE model of the 3-story building scaled model was created using CAD software based on actual geometry to describe the structure's physical properties. The FE model was then imported into CAE software, where the boundary condition and estimated material properties were assigned to determine the effect of random vibration. Through the pairing of Finite Element Analysis results and previous studies, 9 natural frequencies and 9 mode shapes were extracted. The Modal Assurance Criterion (MAC) was used to compare the mode shape of FE results against the OMA to determine the degree of consistency between paired mode shapes. A model updating process was carried out to reduce the discrepancy between the methods. The uncertainties arising from the initial conditions have been discussed in terms of the stiffness of the material used. The updated model allows for an evaluation of the structure's current actions as well as the development of models for a wide range of potential future research scenarios.

The lithium-ion battery (LIB) is widely used in portable devices, power tools and electric vehicles, which becomes one of the most important moving power sources. However, inevitable internal short circuits may cause the pressure inside the battery rising, leading to fire or intensive explosion. In this paper, a finite element (FE) model is established to reasonably capture the major explosion behavior of 18650 battery, one of the most prevailing battery models in electric vehicles, caused by internal short circuit. An explosive load is applied to the 18650 battery FE model based on ABAQUS platform to simulate the internal short circuit. The FE model includes key components such as anode part, cathode part, multi-layered separator and the outside shell. Mechanical parameters are taken from previous studies [1] as well as current mechanical testing, with the consideration of temperature, strain rate and anisotropy effect. Result may provide future in-depth studies to study the lithium-ion battery explosion which are not available from the real-world experiment such to guide the optimal design for safe battery manufacturing.

A finite element based method for estimating natural frequencies of locally damaged homogeneous beams

This paper presents approaches to and the results of finite-element analysis of static buckling in cylindrical sandwich panels. The core layer of the panels is a polylactide honeycomb core 3D printed using the Fused Deposition Modeling (FDM) additive technology. The two thin face layers are made of carbon fiber reinforced polymer. Such structures are promising for use as structural elements of rockets and drones. For them, the determination of stability under longitudinal and radial loads is an important issue. The global buckling of a cylindrical panel under longitudinal loads and the local buckling of a honeycomb core as a plate structure under radial loads are studied. The geometrically nonlinear deformation of a cylindrical panel under a combination of transverse and radial loads is studied. Seven cylindrical sandwich panels with the radius-to-thickness ratio in the range 5 ? R/h ? 50 and a sandwich plate are considered. The effect of the radius of curvature on the characteristics of local and global buckling is investigated. The problem is solved by the finite element method using the ANSYS software system. The convergence of the finite element model was investigated. For this purpose, a strained state under the action of a longitudinal load was studied. The finite-element mesh parameters were selected to ensure the convergence of the results. Two finite element models, an “exact” one and an “approximate” one, were constructed to investigate global buckling under longitudinal loads. The «exact» model includes a honeycomb core represented by its geometry. In the «approximate» model of the sandwich panel, the honeycomb core is replaced with an equivalent homogenized layer. It was found that for longitudinal loads the modes of the global buckling of the cylindrical sandwich panels and the sandwich plate under study are almost the same. It was shown that the critical loads obtained by the «exact» and the «approximate» model are close. It was found that when a cylindrical panel is deformed under the action of a combination of longitudinal and radial subcritical loads, the calculated results for the «exact» and the «approximate» model are close. Therefore, longitudinal buckling can be considered using the homogenized model, which is much simpler in terms of computations.

The primary task of rotary shaft seals is to prevent an unwanted fluid transfer between two areas. In shaft passages of gearboxes, for example, rotary shaft seals avoid the leakage of transmission oil to ambient air. This means the flow in the lubricant film in the sealing gap between the sealing edge and the shaft surface consists of at least two phases. Taking the phenomenon of cavitation into account, the flow consists of three phases. This study aims to provide an in-depth understanding of the multiphase flow in the lubricant film of rotary shaft seals. As experimental studies of the flow processes on a microscale have proven to be quite difficult, a simulation-based approach is applied. Computational fluid dynamics (CFD) serves to compute the transient multiphase flows in the lubricant film in the sealing gap. The computational domain is a three-dimensional microscale model of the lubricant film. The results show the transient hydrodynamic pressure buildup and the dynamic phase interactions during operation. This study provides far-reaching insights into the multiphase flow processes in the lubricant film in the sealing gap and simulation-based evidence of the lubrication and sealing mechanism of rotary shaft seals.