Observation of notch effect in Al6061-T6 specimens under tensile loading using digital image correlation and finite element method

The fracture of ductile materials such as Al6061-T6 usually starts from void nucleation. In this study, we investigated strengthening effect and stress triaxiality behavior in notched Al alloy specimens. Various specimens, one un-notched and two with different U-types of notch, one with large diameter (L-notched) and another with small diameter (S-notched), having the same width were selected. The distribution of strain in the full-field was examined using the digital image correlation (DIC) method. Under the tensile test, S-notched specimens showed a more pronounced strengthening effect than the L-notched specimens. The results of DIC confirmed that the notch tip of the S-notched specimen experienced high strain, while the L-notched specimen experienced high strain at the center. The maximum stress triaxiality moved rapidly from the notch tip to the center with the increase in notch radius over 10 mm. The results of the stress triaxiality analysis by finite element method were in good agreement with the above DIC measurement results and predicted the void generation and fracture sites in L-notched and S-notched specimens.     

Comparison of FRF measurements and mode shapes determined using optically image based, laser, and accelerometer measurements

Today, accelerometers and laser Doppler vibrometers are widely accepted as valid measurement tools for structural dynamic measurements. However, limitations of these transducers prevent the accurate measurement of some phenomena. For example, accelerometers typically measure motion at a limited number of discrete points and can mass load a structure. Scanning laser vibrometers have a very wide frequency range and can measure many points without mass-loading, but are sensitive to large displacements and can have lengthy acquisition times due to sequential measurements. Image-based stereo-photogrammetry techniques provide additional measurement capabilities that compliment the current array of measurement systems by providing an alternative that favors high-displacement and low-frequency vibrations typically difficult to measure with accelerometers and laser vibrometers. Within this paper, digital image correlation, three-dimensional (3D) point-tracking, 3D laser vibrometry, and accelerometer measurements are all used to measure the dynamics of a structure to compare each of the techniques. Each approach has its benefits and drawbacks, so comparative measurements are made using these approaches to show some of the strengths and weaknesses of each technique. Additionally, the displacements determined using 3D point-tracking are used to calculate frequency response functions, from which mode shapes are extracted. The image-based frequency response functions (FRFs) are compared to those obtained by collocated accelerometers. Extracted mode shapes are then compared to those of a previously validated finite element model (FEM) of the test structure and are shown to have excellent agreement between the FEM and the conventional measurement approaches when compared using the Modal Assurance Criterion (MAC) and Pseudo-Orthogonality Check (POC).     

Investigations on exit burr formation mechanisms based on digital image correlation and numerical modeling

Abstract

Requirements on burr height and burr amount on machined parts are getting stricter. This leads to method development from manufacturing companies to predict burr distribution and its size along part edges. A deeper understanding of burr formation mechanisms will assist to more accurate model development. This study aims to analyze the exit burr formation, which is formed during orthogonal cutting of a brittle cast aluminum alloy. A customized digital image correlation (DIC) system with the help of a high-speed camera was used to measure the displacements fields. It calculates strain fields during burr initiation and development in orthogonal cutting of T7 heat-treated cast aluminum alloy ENAC-AlSi7Mg0.3 as well. Those results are then qualitatively compared with a numerical model of the burr with chamfer formation developed and simulated using a finite element method, to ensure a good correspondence between experiments and simulation. This model is used to complete the DIC study of burr with chamfer formation mechanisms during crack propagation leading to chamfer formation. The analysis of numerically obtained stress triaxiality fields and of DIC observations from experiments are compared to the assumptions made from analytical models. Finally, necessary improvements of an existing burr formation analytical model are proposed.     

Experimental modal analysis on the core support barrel of reactor internals using a scale model

The vibration of core support barrel (CSB) in a typical pressurized water reactor is studied by experimental and finite element analysis methods. Free vibration models are built and tested for the 1/13.7th scale of Ulchin Nuclear (UCN) Unit 3 & 4. Finite element model is established by plate model with shell elements. Finite element and measurement analyses are performed with respect to the two type of cylindrical shell models with and without holes. Test results on CSB vibration models are presented and compared with finite element analysis results. Various techniques are used to compare the measurement and analysis results.     

二维数字图像相关方法的拉伸实验误差分析

对数字图像相关(DIC)方法的拉伸实验误差进行了系统分析。通过刚体运动实验,从软件模拟计算和硬件两方面研究了DIC方法的实验误差,同时,根据成像原理,分析了离面位移对实验结果的影响。为了检验测试系统的测量精度,将DIC方法与多晶铜试样拉伸实验相结合,比较了不同实验条件下DIC方法与应变片测量的结果,分析认为测量误差主要来源于摄像机噪声及离面位移。鉴于这两种误差难以消除,探索了一种误差修正方法,对系统误差进行修正并得到满意结果。     

某型大尺寸进气道测量耙振动与应力相关性试验研究

为了解决应变计测量法在试飞中对测量耙应力难以监控的问题,对自行设计的某型大尺寸进气道测量耙进行振动试验,建立测量耙振动与应力的相关性,实现利用测量耙振动信息监视分析测量耙应力的目的。通过扫频和定频试验,得到了相应的振动和应变试验数据。通过试验数据分析,得到了耙的固有频率,并根据各测点应变与振动的相关性初步建立了耙的振动与应力之间的关系方程,为后续试飞中测量耙安全监控提供一定试验基础和依据。     

数字图像相关法测量金属薄板焊接的全场变形

提出了一种基于数字图像相关法和双目视觉技术的全场三维变形测量方法来测量金属薄板焊接过程中的高温变形.首先,提出一种基于种子点的高精度图像匹配算法求解相关匹配非线性优化初值.然后,介绍了三维坐标重建以及三维位移、三维应变的求解算法.最后,借助于VC+ +6.0开发环境,研制了用于薄板焊接全场变形测量的实验系统.为验证本文方法在材料力学性能实验方面的可行性,利用标准材料试验机和自主研制的图像采集装置设计了钢试件的标准拉伸实验,并采用Q235板材件进行了焊接变形测量实验.实验表明:本文方法的应变测量精度为0.5％,与引伸计的测量结果基本相当;与传统的测量方法相比,提出的方法可以更全面、更直观地测量金属薄板在整个焊接过程中的三维移和应变场,并且测得的3个方向的位移变化曲线过渡自然、数据合理,是研究焊接变形规律的有效手段.     

数字散斑相关方法测定混凝土表面位移场

利用数字散斑相关方法,研究了混凝土试块在压缩载荷作用下的表面变形情况,绘制了混凝土试块表面x方向和y方向的位移场图。实验表明,数字散斑相关方法能够有效测定混凝土表面的变形分布情况,为进一步讨论混凝土材料的本构关系提供基础。     

A constant scanning LDV technique for cylindrical structures: Simulation and measurement

The reliance of the aerospace industry on finite element models during the design of new products requires the best possible models for the prediction of the dynamic behaviour and so it is usually necessary to validate an original model using some additional reference data as the basis—usually data measured on a test structure. Finite element model updating can lead to the required accuracy, and while attempts are under way to minimise the required experimental testing involved in the process, measurements still are an integral part of the procedure. To improve the validation process, a major aim of current experimental research is to provide a more complete set of data from a single experiment in a shorter amount of time, so as to increase the overall efficiency of the updating routine. To this end, a new continuously scanning laser Doppler vibrometery measurement technique is presented for application to cylindrical structures. It allows the measurement of the dynamic behaviour of a cylindrical structure with a previously unachievable spatial resolution in a much shorter time than conventional measurement methods. The introduced method is evaluated through a detailed simulation in order to investigate its robustness and to ensure data quality, and the results from a proof-of-concept test rig are presented.     

A reduced order,test verified component mode synthesis approach for system modeling applications

Component mode synthesis (CMS) is a very common approach used for the generation of large system models. In general, these modeling techniques can be separated into two categories: those utilizing a combination of constraint modes and fixed interface normal modes and those based on a combination of free interface normal modes and residual flexibility terms. The major limitation of the methods utilizing constraint modes and fixed interface normal modes is the inability to easily obtain the required information from testing; the result of this limitation is that constraint mode-based techniques are primarily used with numerical models.An alternate approach is proposed which utilizes frequency and shape information acquired from modal testing to update reduced order finite element models using exact analytical model improvement techniques. The connection degrees of freedom are then rigidly constrained in the test verified, reduced order model to provide the boundary conditions necessary for constraint modes and fixed interface normal modes.The CMS approach is then used with this test verified, reduced order model to generate the system model for further analysis. A laboratory structure is used to show the application of the technique with both numerical and simulated experimental components to describe the system and validate the proposed approach.Actual test data is then used in the approach proposed. Due to typical measurement data contaminants that are always included in any test, the measured data is further processed to remove contaminants and is then used in the proposed approach. The final case using improved data with the reduced order, test verified components is shown to produce very acceptable results from the Craig–Bampton component mode synthesis approach.Use of the technique with its strengths and weaknesses are discussed.