Finite element analysis and optimization of composite wheelchair wheels

A methodology for the design of Paralympics wheelchair wheels has been developed and provided a framework for comparison between design solutions. Finite element analysis was used as a tool to develop an understanding of wheel design, provide a basis for evaluation of design solutions, and as a mean of design optimisation. A finite element model of an existing wheel design was created and analysed. It was found that the pushrim was significantly over designed for the application. As such, wheel improvement focused on redesign of this component. A number of design solutions were analysed and compared based on weight, rotational moment of inertia, side profile surface area, and wheel stiffness. From this, it was decided that a thin pushrim attached via spokes to the rim and the hub in a tangential spoking pattern would offer the best solution.     

A meso-scale finite element model for simulating free-edge effect in carbon/epoxy textile composite

Textile composites are well known for their excellent through thickness properties and impact resistance. In this study, a representative unit cell model of a triaxial braided composite is developed based on the composite fiber volume ratio, specimen thickness and microscopic image analysis. A meso-scale finite element (FE) mesh is generated based on the detailed unit cell dimensions and fiber bundle geometry parameters. The fiber bundles are modeled as unidirectional fiber reinforced composites. A micromechanical finite element model was developed to predict the elastic and strength material properties of each unidirectional composite by imposing correct boundary conditions that can simulate the actual deformation within the braided composite. These details are then applied in the meso-mechanical finite element model for a 0°/+60°/−60° triaxially braided T700s/E862 carbon/epoxy composite. Model correlations are conducted by comparing numerical predicted and experimental measured axial tension and transverse tension response of a straight-sided, single-layer (one ply thick) coupon. By applying a periodic boundary condition in the loading direction, the meso model captures the local damage initiation and global failure behavior, as well as the periodic free-edge warping effect. The failure mechanisms are studied using the field damage initiation contours and local stress history. The influence of free-edge effect on the failure behaviors is investigated. The numerical study results reveal that this meso model is capable of predicting free-edge effect and allows identification of its impact on the composite response.     

Finite element formulation of a heat transfer problem for an axisymmetric composite structure

By using weighted residual method, the finite element formulation of a heat transfer problem for axisymmetric composite structures is established from the heat transfer differential equations expressed by heat fluid density. A few examples are included to indicate that the heat transfer anisotropy has an important effect on temperature field and to prove the accuracy and effectiveness of the finite element formulation.Aknowledgement Special thanks are due to the National Natural Science Foundation of China (No: 10272037) for supporting the present work.     

Multiscale modeling of the impact of textile fabrics based on hybrid element analysis

In this work, a multi scale modeling approach has been developed to simulate the impact of woven fabrics using a finite element (FE) analysis. A yarn level of resolution is used in the model. This approach, referred to as the hybrid element analysis (HEA) is based on decreasing the complexity of the finite element model with distance away from the impact zone based on the multiscale nature of the fabric architecture and the physics of the impact event. Solid elements are used to discretize the yarns around the impact region, which transition to shell elements in the surrounding region. A new method for modeling the shell yarns is incorporated that more accurately represents the contours of the yarn cross section. Impedances have been matched across the solid–shell interface to prevent interfacial reflections of the longitudinal strain wave. The HEA method is validated by first applying it to the FE model of a single yarn for which an analytical solution is known. The HEA method is then applied to a woven fabric model and validated by comparing it against a baseline model consisting of yarns discretized using only solid elements.     

Predictive modelling for optimization of textile composite forming

Wrinkling often occurs during textile composite forming and is a major problem for manufacturers. The prediction of this defect is, therefore, of major importance for the design and optimization of textile composite structures. Numerical simulations of forming for textile composites over a hemisphere have been conducted using a rate/temperature-dependent hybrid FE model. The hybrid FE model incorporates a fully predictive multi-scale energy model which determines the shear resistance of the textile composite sheet. The effects of varying the normal force distribution across the edges of the blank and blank size, together with the effect of changes in forming temperature on the final fibre pattern and wrinkling behaviour, are investigated. Predictions are evaluated against press-formed components. The results from the simulation and the experiments have good correlation and show that wrinkling can be minimized by optimizing the force distribution around the edge of the manufacturing tool and by careful choice of forming temperature.     

Mesh design in finite element analysis of post-buckled delamination in composite laminates

The role of mesh design in the post-buckling analysis of delamination in composite laminates is addressed in this paper. The determination of the strain energy release rate (SERR) along the crack front is central to the analysis. Frequently, theoretical analysis is limited to treatment of the problem in two dimensions, since considerable complexity is encountered in extending the analysis to three dimensions. However, many practical problems of embedded delamination in composite laminates are inherently three-dimensional in nature. Although in such cases, the finite element (FE) method can be employed, there are some issues that must be examined more closely to ensure physically realistic models. One of these issues is the effect of mesh design on the determination of the local SERR along the delamination front. There are few studies that deal with this aspect systematically. In this paper, the effect of mesh design in the calculation of SERR in two-dimensional (2D) and three-dimensional (3D) FE analyses of the post-buckling behavior of embedded delaminations is studied and some guidelines on mesh design are suggested. Two methods of calculation of the SERR are considered: the virtual crack closure technique (VCCT) and crack closure technique (CCT). The 2D analyses confirm that if the near-tip mesh is symmetric and consists of square elements, then the evaluation of the SERR is not sensitive to mesh refinement, and a reasonably coarse mesh is adequate. Despite agreement in the global post-buckling response of the delaminated part, the SERR calculated using different unsymmetrical near-tip meshes could be different. Therefore, unsymmetrical near-tip meshes should be avoided, as convergence of the SERR with mesh refinement could not be assured. While the results using VCCT and CCT for 2D analyses agree well with each other, these techniques yield different quantitative results when applied to 3D analyses. The reason may be due to the way in which the delamination growth is modeled. The CCT allows simultaneous delamination advance over finite circumferential lengths, but it is very difficult to implement and the results exhibit mesh dependency. Qualitatively, however, the two sets of results show similar distributions of Mode I and Mode II components of the SERR. This is fortunate, since the VCCT is relatively easy to implement.     

Finite element simulation of the braiding process for arbitrary mandrel shapes

An approach to simulate the two-dimensional braiding process using a commercial explicit finite element software is presented. Preforms with generic shapes are analyzed. A procedure is given to determine the boundary conditions of the braiding mandrel including the extraction of necessary geometry information. The friction coefficients needed as input parameters are determined in separate tests. The simulation results are processed with an algorithm that derives the braiding angle and the axial spacing of the yarns. For validation, a generic mandrel geometry is overbraided and a method to compare simulation and experiment is presented. The preform is analyzed using an optical sensor. The measurements are filtered and averaged. The simulation model is validated by comparing the braiding angle of simulation and experiment. A good agreement between simulation and experimental results is achieved.     

Finite element analysis of postbuckling and delamination of composite laminates using virtual crack closure technique

The two-dimensional and three-dimensional parametric finite element analysis (FEA) of composite flat laminates with two through-the-width delamination types: 0₄/(±θ)₆//0₄ and 0₄//(±θ)₆//0₄ (θ = 0°, 45°, and “//” denotes the delaminated interface) under compressive load are performed to explore the effects of multiple delaminations on the postbuckling properties. The virtual crack closure technique which is employed to calculate the energy release rate (ERR) for crack propagation is used to deal with the delamination growth. Three typical failure criteria: B-K law, Reeder law and Power law are comparatively studied for predicting the crack propagation. Effects of different mesh sizes and pre-existing crack length on the delamination growth and postbuckling properties of composite laminates are discussed. Interaction between the delamination growth mechanisms for multiple cracks for 0₄//(±θ)₆//0₄ composite laminates is also investigated. Numerical results using FEA are also compared with those by existing models and experiments.     

Finite element analysis using interfragmentary strain theory for the fracture healing process to which composite bone plates are applied

The present paper deals with finite element analyses to estimate the healing efficiency of fractured long bones to which various composite bone plates are applied. To estimate the callus modulus according to the healing period, interfragmentary strain theory was used, and the iterative process for updating the newly determined callus properties in every finite element was implemented by a user-defined sub-routine constructed by the Python code. The results of analysis revealed that a composite bone plate made of a plain weave carbon/epoxy composite whose Young’s modulus was in the range of 30–70 GPa produced a positive effect on the healing efficiency relieving stress-shielding effect. This result can be used in the detailed design of high-performing composite bone plates to determine more effective shapes and stacking sequences for better healing efficiency.     

Design of a fibrous composite preform for wind turbine rotor blades

The present work addresses the different factors and challenges one must cope with in the design process of a composite preform used for the load-carrying main laminate of a wind turbine rotor blade. The design process is split up into different key elements, each of which are presented and discussed separately. The key elements are all interconnected, which complicate the design process and involves an iterative procedure. The aim is to provide an overview of the process that governs the design of composite preforms for wind turbine blades. The survey can be used as an information source on composite preform manufacturing. Basic knowledge on wind turbine blade technology and composites is assumed.     

Finite element analysis of substation composite insulators

Composite insulators are rapidly replacing their porcelain counterparts in electrical substation applications. These insulators consist of a glass-reinforced polymer (GRP) rod, with two metal end fittings radially crimped onto the ends of the rod during assembly. In this paper, axisymmetric finite element models are developed to evaluate the mechanical performance of composite insulators under externally applied axial compression. The analyses are performed by assuming both a perfectly bonded interface between the composite rod and the end fittings, and an imperfect interface which permits large relative sliding with Coulomb friction. Results indicate that the perfect interface model is unrealistic since it predicts singular stresses at the interface comer and an overall linear structural response. On the other hand, the imperfect interface model is found to simulate accurately the structural non-linearity caused by relative sliding of the GRP rod within the end fittings. The imperfect interface model has therefore been used to evaluate the effects of interface friction, and the extent of crimping, on the maximum load-bearing capacity of substation composite insulators.     

Finite element analysis of free-edge stresses in composite laminates under mechanical an thermal loading

In this paper, a multi-particle finite element [Nguyen VT, Caron JF. A new finite element for free edge effect analysis in laminated composites. Comput Struct, accepted for publication] is applied for general laminated and is shown to be capable of simultaneously predicting global and local responses. The analysis of free-edge stresses of composite laminates subjected to mechanical and thermal loads is performed using this C^o${\mathbb{C}}^o$ eight-node layer-wise finite element after a classical bending validation. Laminates with finite dimensions are considered and three-dimensional out-of-plane stresses in the interior and near the free edges are evaluated. The results obtained with this finite element modelling are compared with those available in the literature. The present calculation provides accurate stresses and can be utilised as and operational tool to predict interlaminar stresses under the loads of mechanical and thermal combined.     

Post-buckling behaviour of flat stiffened composite panels: Experiments vs. analysis

The paper is focused on the development of a validated procedure for modelling, by means of Finite Element tools, the post-buckling behaviour of stiffened composite flat panels subjected to compression loads. The experimental data for model validation were collected during a test campaign on two sets of CFRP flat stiffened panels.     

High performance thermoplastic composite from flat knitted multi-layer textile preform using hybrid yarn

Modern flat knitting machines using high performance yarns are able to knit fabrics including the reinforcement yarns arranged differently into knit structures. Due to their improved mechanical properties, composites made from multi-layer knit fabrics show great potential in lightweight applications. This paper reports on the development of flat knitted multi-layer textile preforms for high performance thermoplastic composites using hybrid yarns made of glass (GF) and polypropylene (PP) filaments. Such textile preforms with different reinforcements were used to consolidate into 2D thermoplastic composites. Moreover, the mechanical properties of these composites were studied. The mechanical properties of 2D composites were found to be greatly affected by different arrangements of reinforcement yarns. The integration of reinforcement yarns as biaxial inlays (warp and weft yarns) is found to be the best solution for knitting, whereas tuck stitch shaped and unidirectional arranged reinforcements offer also promising application possibilities.     

Formulation of reference surface element and its applications in dynamic analysis of delaminated composite beams

This paper presents a new finite element formulation, referred to as reference surface element (RSE) model, for numerical prediction of dynamic behaviour of delaminated composite beams and plates using the finite element method. The RSE formulation can be readily incorporated into all elements based on the Timoshenko beam theory and the Reissner–Mindlin plate theory taking into account the transverse shear deformations. The ‘free model' and ‘constrained model' for dynamic analysis of delaminated composite beams and/or plates have been unified in this RSE formulation. The RSE formulation has been applied to an existing 2-node Timoshenko beam element taking into account the transverse shear deformations and the bending–extension coupling. Frequencies and vibration mode shapes are determined through solving an eigenvalue problem. Numerical results show that the present RSE model is reliable and practical when used to predict frequencies and mode shapes of delaminated composite beams. The RSE formulation has also been used to investigate the effects of the number, size and interfacial loci of delaminations on frequencies and mode shapes of composite beams.     

Finite element analysis of shear punch testing and experimental validation

In this work, finite element analysis (FEA) of the shear punch testing is carried out to study the specimen deformation up to yielding and the results are compared and validated with experimental data for four different materials. The elastic portion of the FEA generated load–displacement curve overlaps with the corresponding experimental curve only when the fixture compliances are eliminated in experiments. Based on through thickness plasticity in the FEA study, the shear yield stress estimated at an offset of 0.15% of normalized displacement compares well with the experimentally determined shear yield strength and satisfies the von Mises yield relation _σys=1.73_τys${\sigma }_{\mathit{ys}}=1.73{\tau }_{\mathit{ys}}$. The effects of die-punch clearance and specimen thickness on shear yield strength studied using FEA are also discussed.     

Finite element buckling analysis of rotationally periodic laminated composite shells

A finite element (FE) buckling analysis of rotationally periodic laminated composite shells is performed in this paper. Because the buckling mode of such structures is characterized as rotationally periodic, a corresponding FE buckling analysis scheme is proposed to reduce the computational expenses. Moreover, a new kind of relative degrees‐of‐freedom element is developed, which can be connected to other solid elements with ease and can yield satisfactory results with a relatively coarse FE mesh. Numerical results of two laminated cylindrical shells subjected to lateral pressure are compared with theoretical ones. The good agreement of them shows the validity of this new computational strategy. Finally, a practical structure is analysed to demonstrate the advantage of this method. Copyright © 2001 John Wiley & Sons, Ltd.     

Simulation of 3D interlock composite preforming

The ply to ply interlock fabric preform enables to manufacture, by R.T.M. process, thick composite parts that are resistant to delamination and cracking. Numerical simulation of interlock reinforcement forming allows to determine conditions for feasibility of the process and above all to know the position of fibres in the final composite part. For this forming simulation, specific hexahedral finite elements made of segment yarns are proposed. Position of each yarn segment within the element is taken into account. This avoids determination of a homogenized equivalent continuous law that would be very difficult considering the complexity of the weaving. Transverse properties of fabric are taken into account within a hypoelastic constitutive law. A set of 3D interlock fabric forming simulations shows the efficiency of the proposed approach.     

The finite element analysis of composite laminates and shell structures subjected to low velocity impact

In this investigation, the composite laminate and shell structures subjected to low velocity impact are studied by the ANSYS/LS-DYNA finite element software. The contact force is calculated by the modified Hertz contact law in conjunction with the loading and unloading processes. In the case of composite laminate, the impact-induced damage including matrix cracking and delamination are predicted by the appropriated failure criteria and the damaged area are plotted. Two types of shell structure, cylindrical and spherical shells, are considered in this paper. The effects of various parameters, such as shell curvature, clamped or simple supported boundary conditions and impactor velocity are examined through the parametric study. Numerical results show that structures with greater stiffness, such as smaller curvature and clamped boundary condition, result to a larger contact force and a smaller deflection. The impact response of the structure is proportional to the impactor velocity.     

Finite element analysis of bone loss around failing implants

Dental implants induce diverse forces on their surrounding bone. However, when excessive unphysiological forces are applied, resorption of the neighbouring bone may occur. The aim of this study was to assess possible causes of bone loss around failing dental implants using finite element analysis. A further aim was to assess the implications of progressive bone loss on the strains induced by dental implants. Between 2003 and 2009 a total of 3700 implant operations were performed in a private clinic. Ten patients with 16 fixtures developed severe marginal bone defects. Finite element analysis was used to assess the effective strains produced at the bone-implant interface under unidirectional axial loading. These simulations were carried out on 4 specific implant types – Camlog Plus, Astra Osseo Speed, Straumann BL and Straumann S/SP. All implant types exhibited degraded performance under circular and horizontal bone loss conditions. This is evidenced by increased distribution of pathological strain intensities (>3000 με), in accordance with the mechanostat hypothesis, in the surrounding bone. Among the implants, the Camlog design seemed to have performed poorly, especially at the chamfer in the implant collar (>25000 με). Implants are designed to perform under nearly ideal conditions from insertion till osseointegration. However, when the surrounding bone undergoes remodelling, implant geometries can have varied performance, which in some cases can exacerbate bone loss. The results of this study indicate the importance of evaluating implant geometries under clinically observed conditions of progressive bone loss.