Finite element simulations of ultrasonically assisted turning

Ultrasonically assisted turning is a promising machining technology, where high frequency vibration (f≈20 kHz) with an amplitude a≈10 μm is superimposed on the movement of the cutting tool. Ultrasonic turning yields a noticeable decrease in cutting forces, heat and noise radiation, as well as a superior surface finish, comparing to the conventional machining technology. The present study utilizes both experimental techniques and numerical (finite element) simulations to analyze the microstructural processes at the cutting tool–chip interface. High-speed filming of the chip–tool interaction zone during cutting and microstructural and nanoindentation analyses of the machined surfaces are used to compare process zones and deformation processes for both conventional and ultrasonically assisted technologies. The suggested finite-element (FE) model, which utilizes MSC Marc/Mentat general FE code, provides a transient analysis for an elasto-plastic material, accounting for the frictionless contact interaction between a cutter and workpiece as well as material separation in front of the cutting edge. A detailed analysis of cutting for a single cycle of ultrasonic vibration is carried out for isothermal conditions. Differences between conventional and ultrasonic turning in stress distribution in the process zone and contact conditions at the tool/chip interface are investigated.     

A bridging transition technique for the combination of meshfree method with finite element method in 2D solids and structures

For certain continuum problems, it is desirable and beneficial to combine two different methods together in order to exploit their advantages while evading their disadvantages. In this paper, a bridging transition algorithm is developed for the combination of the meshfree method (MM) with the finite element method (FEM). In this coupled method, the MM is used in the sub-domain where the MM is required to obtain high accuracy, and the FEM is employed in other sub-domains where FEM is required to improve the computational efficiency. The MM domain and the FEM domain are connected by a transition (bridging) region. A modified variational formulation and the Lagrange multiplier method are used to ensure the compatibility of displacements and their gradients. To improve the computational efficiency and reduce the meshing cost in the transition region, regularly distributed transition particles, which are independent of either the meshfree nodes or the FE nodes, can be inserted into the transition region. The newly developed coupled method is applied to the stress analysis of 2D solids and structures in order to investigate its’ performance and study parameters. Numerical results show that the present coupled method is convergent, accurate and stable. The coupled method has a promising potential for practical applications, because it can take advantages of both the MM and FEM when overcome their shortcomings.     

An object-oriented finite element framework for multiphysics phase field simulations

The phase field approach is a powerful and popular method for modeling microstructure evolution. In this work, advanced numerical tools are used to create a framework that facilitates rapid model development. This framework, called MARMOT, is based on Idaho National Laboratory’s finite element Multiphysics Object-Oriented Simulation Environment. In MARMOT, the system of phase field partial differential equations (PDEs) are solved simultaneously together with PDEs describing additional physics, such as solid mechanics and heat conduction, using the Jacobian-Free Newton Krylov Method. An object-oriented architecture is created by taking advantage of commonalities in the phase field PDEs to facilitate development of new models with very little effort. In addition, MARMOT provides access to mesh and time step adaptivity, reducing the cost for performing simulations with large disparities in both spatial and temporal scales. In this work, phase separation simulations are used to show the numerical performance of MARMOT. Deformation-induced grain growth and void growth simulations are also included to demonstrate the muliphysics capability.     

A coupled meshfree/finite element method for automotive crashworthiness simulations

Mesh distortion induced numerical instability is a major roadblock in automotive crashworthiness finite element simulations. Remedies such as wrapping elements with null shells and deletion of distorted meshes have been adopted but none of them seems robust enough to survive various scenarios. Meshfree methods have been developed over the past almost twenty years in view of their capabilities in dealing with large material deformation and separation, but have remained in academic research due to their unaffordable high computational cost in solving large-scale industrial applications. This paper presents a coupled meshfree/finite-element method which allows engineers to model the severe deformation area with the meshfree method while keeping the remaining area modeled by the finite element methods. The method is implemented into LS-DYNA version 971 and its later versions so that it is available for automotive crashworthiness simulations. In the paper, one linear patch test and three crash examples are presented to demonstrate the accuracy of the meshfree formulation, its effectiveness in resolving mesh distortion difficulty, and the efficiency of the coupled meshfree/finite element solver in handling large-scale models.     

Thermomechanical advantages of functionally graded dental posts: A finite element analysis

This study aimed to fabricate dental posts with functionally graded structures comprised of zirconia, titanium, and hydroxyapatite and compare their thermomechanical behavior with homogeneous zirconia and titanium posts in simulated models of upper central incisor. The results indicated the gradual behavior of functionally graded dental posts in terms of physical and mechanical properties. The finite element analysis revealed a more efficient equilibration to the oral environment after removing the thermal stress in functionally graded dental post compared to the homogeneous counterparts. Therefore, the functionally graded structures could reduce the stress/strain concentrations and interfacial stresses in root canal and minimize the likelihood of root fracture.     

Micromechanical formulation and 3D finite element modeling of microinstabilities in composites

A 3D micromechanical formulation and a FE-model of fiber micro-buckling in materials with isotropic and transversal isotropic fibers in compression is presented. Three variants of geometrical modeling of the characteristic cell are proposed and compared. An appropriate one is then selected. An eigenvalue analysis of a characteristic cell is performed. The results show that the fiber anisotropy reduces significantly the critical loads and must be taken into account.     

Refining constitutive relation by integration of finite element simulations and Gleeble experiments

Thermo-mechanical coupled finite element calculations were carried out to simulate the Gleeble compression of the samples of a titanium alloy (Ti60), and the results are analyzed and compared with the actual compression tests conducted on a Gleeble 3800 thermo-mechanical simulator. The changes in temperature, stress and strain distribution in the samples and the source of error on the constitutive relations from Gleeble hot compression test were analyzed in detail. Both simulations and experiments showed that the temperature distribution in the specimen is not uniform during hot compression, resulting in significant deformation inhomogeneity and non-ignorable error in the flow stress strain relation, invalidating the uniform strain assumption commonly assumed when extracting the constitutive relation from Gleeble tests. Based on the finite element simulations with iterative corrections, we propose a scheme to refine the constitutive relations from Gleeble tests.     

Generalized finite element approaches for analysis of localized thermo‐structural effects

This work addresses computational modeling challenges associated with structures subjected to sharp, local heating, where complex temperature gradients in the materials cause three‐dimensional, localized, intense stress and strain variation. Because of the nature of the applied loadings, multiphysics analysis is necessary to accurately predict thermal and mechanical responses. Moreover, bridging spatial scales between localized heating and global responses of the structure is nontrivial. A large global structural model may be necessary to represent detailed geometry alone, and to capture local effects, the traditional approach of pre‐designing a mesh requires careful manual effort. These issues often lead to cumbersome and expensive global models for this class of problems. To address them, the authors introduce a generalized FEM (GFEM) approach for analyzing three‐dimensional solid, coupled physics problems exhibiting localized heating and corresponding thermomechanical effects. The capabilities of traditional hp‐adaptive FEM or GFEM as well as the GFEM with global–local enrichment functions are extended to one‐way coupled thermo‐structural problems, providing meshing flexibility at local and global scales while remaining competitive with traditional approaches. The methods are demonstrated on several example problems with localized thermal and mechanical solution features, and accuracy and (parallel) computational efficiency relative to traditional direct modeling approaches are discussed. Copyright © 2015 John Wiley & Sons, Ltd.     

An Abaqus implementation of the extended finite element method

In this paper, we introduce an implementation of the extended finite element method for fracture problems within the finite element software ABAQUS^TM. User subroutine (UEL) in Abaqus is used to enable the incorporation of extended finite element capabilities. We provide details on the data input format together with the proposed user element subroutine, which constitutes the core of the finite element analysis; however, pre-processing tools that are necessary for an X-FEM implementation, but not directly related to Abaqus, are not provided. In addition to problems in linear elastic fracture mechanics, non-linear frictional contact analyses are also realized. Several numerical examples in fracture mechanics are presented to demonstrate the benefits of the proposed implementation.     

A cohesive finite element for quasi-continua

In this paper, a cohesive finite element method (FEM) is proposed for a quasi-continuum (QC), i.e. a continuum model that utilizes the information of underlying atomistic microstructures. Most cohesive laws used in conventional cohesive FEMs are based on either empirical or idealized constitutive models that do not accurately reflect the actual lattice structures. The cohesive quasi-continuum finite element method, or cohesive QC-FEM in short, is a step forward in the sense that: (1) the cohesive relation between interface traction and displacement opening is now obtained based on atomistic potentials along the interface, rather than empirical assumptions; (2) it allows the local QC method to simulate certain inhomogeneous deformation patterns. To this end, we introduce an interface or discontinuous Cauchy–Born rule so the interfacial cohesive laws are consistent with the surface separation kinematics as well as the atomistically enriched hyperelasticity of the solid. Therefore, one can simulate inhomogeneous or discontinuous displacement fields by using a simple local QC model. A numerical example of a screw dislocation propagation has been carried out to demonstrate the validity, efficiency, and versatility of the method. An erratum to this article can be found at     

Three-dimensional finite element simulations of mixed-mode stable tearing crack growth experiments

Mixed-mode stable tearing crack growth events in Arcan plate specimens made of aluminum alloy 2024-T3 are simulated using three-dimensional (3D) finite element methods. A modeling/simulation procedure utilizing a mixed-mode CTOD fracture criterion and the custom 3D crack growth simulation software, CRACK3D, with an automatic local re-meshing option is demonstrated. Simulation predictions of the load-crack extension curve and the in-plane curvilinear crack growth path are compared with experimental measurements for various mixed-mode loading cases. Issues such as the effects of near-tip finite element size and crack extension increment size on simulation predictions are investigated.     

A complete finite element treatment for the fully coupled implicit ALE formulation

This paper presents a complete derivation and implementation of the Arbitrary Lagrangian Eulerian (ALE) formulation for the simulation of large deformation quasi-static and dynamic problems. While most of the previous work done on ALE for dynamic applications was mainly based on operator split and explicit calculations, this work derives the quasi-static and dynamic ALE equations using a fully coupled implicit approach. Full expression for the ALE virtual work equations and finite element matrices are given. Time integration relations for the dynamic equations are also derived. Several quasi-static and dynamic large deformation applications are solved and presented.     

A semi-analytical finite element model for the analysis of laminated 3D axisymmetric shells: Bending, free vibration and buckling

A general semi-analytical finite element model is developed for bending, free vibration and buckling analysis of shells of revolution made of laminated orthotropic elastic material. The 3D elasticity theory is used and the equations of motion are obtained by expanding the displacement field and load in the Fourier series in terms of the circumferential coordinate, θ. The coefficients of the expansion are functions of (r, z), and they are approximated using the finite element method. This leads to a semi-analytical finite element in the (r, z) plane. The element is validated by comparing the present results with the analytical and numerical solutions available in the literature.     

Analysis of acoustic resonator with shape deformation using finite element method

An acoustic resonator with shape deformation has been analysed using the finite element method. The shape deformation is such that the volume of the resonator remains constant. The effect of deformation on the resonant frequencies is studied. Deformation splits the degenerate frequencies.     

The finite element discretized symplectic method for interface cracks

The method of symplectic series discretized by finite element is introduced for the stress analysis of structures having cracks at the interface of dissimilar materials. The crack is modeled by the conventional finite elements dividing into two regions: near and far fields. The unknowns in the far field are as usual. In the near field, a Hamiltonian system is established for applying the method of separable variables and the solutions are expanded in exact symplectic eigenfunctions. By performing a transformation from the large amount of finite element unknowns to a small set of coefficients of the symplectic expansion, the stress intensity factors, the displacements and stresses in the singular region are obtained simultaneously without any post-processing. The numerical results are obtained for various cracks lying at the bi-material interface, and are found to be in good agreement with the reference solutions for the interface crack problems. Some practical examples are also given.     

Expert systems and finite element structural analysis — a review

Finite element analysis of many engineering systems is practised more as an art than as a science. It involves high level expertise (analytical as well as heuristic) regarding problem modelling (e.g. problem specification, choosing the appropriate type of elements etc.), optical mesh design for achieving the specified accuracy (e.g. initial mesh selection, adaptive mesh refinement), selection of the appropriate type of analysis and solution routines and, finally, diagnosis of the finite element solutions. Very often such expertise is highly dispersed and is not available at a single place with a single expert. The design of an expert system, such that the necessary expertise is available to a novice to perform the same job even in the absence of trained experts, becomes an attractive proposition. In this paper, the areas of finite element structural analysis which require experience and decision-making capabilities are explored. A simple expert system, with a feasible knowledge base for problem modelling, optimal mesh design, type of analysis and solution routines, and diagnosis, is outlined. Several efforts in these directions, reported in the open literature, are also reviewed in this paper.     

Monte Carlo simulation of polycrystalline microstructures and finite element stress analysis

A two-dimensional numerical model of microstructural effects is presented, with an aim to understand the mechanical performance in polycrystalline materials. The microstructural calculations are firstly carried out on a square lattice by means of a 2-D Monte Carlo (MC) simulation for grain growth, then the conventional finite element method is applied to perform stress analysis of a plane strain problem. The mean grain size and the average stress are calculated during the MC evolution. The simulation result shows that the mean grain size increases with the simulation time, which is about 3.2 at 100 Monte Carlo step (MCS), and about 13.5 at 5000 MCS. The stress distributions are heterogeneous in materials because of the existence of grains. The mechanical property of grain boundary significantly affects the average stress. As the grains grow, the average stress without grain boundary effect slightly decreases as the simulation time, while the one with strengthening effect significantly decreases, and the one with weakening effect increases. The average stress and the grain size agree well with the Hall–Petch relationship.     

Developments in ultrasonic modeling with finite element analysis

An overview is given of finite element analysis and its application to the modeling of ultrasonic nondestructive evaluation phenomena. Following a discussion of the underlying weighted residual methodology, a mass-lumping technique is described which results in an efficient computer implementation for 2D geometries. Code predictions are compared with both analytical and experimental results, and data from studies of attenuation, anisotropy, defect interactions, and surface waves are given. Initial results from a full 3D formulation are also shown.     

Solving anti-plane problems of piezoelectric materials by the Trefftz finite element approach

Applications of the Trefftz finite element method to anti-plane electroelastic problems are presented in this paper. A dual variational functional is constructed and used to derive Trefftz finite element formulation. Special trial functions which satisfy boundary conditions are also used to develop a special purpose element with local defects. The performance of the proposed element model is assessed by an example and comparison is made with results obtained by other approaches. The Trefftz finite element approach is demonstrated to be ideally suited for the analysis of the anti-plane problem.The work was performed under the auspices of an Australian Professorial Fellowship Program with grant number DP0209487 and 21st Century Education Promotion Key project from Tianjin University.     

Elasto-plastic finite element analysis of a crack in an infinite plate

The elastic support method was recently developed to simulate the effects of unbounded solids in the finite element analysis of stresses and displacements. The method eliminates all the computational disadvantages encountered in the use of `infinite' elements or coupled finite element boundary element methods while retaining all the computational advantages of the finite element method. In this paper, the method is extended to the elasto-plastic analysis of fracture in infinite solids by using the load increment approach and including the effects of strain hardening. Numerical tests and parametric study are conducted by analysing a straight crack in an infinite plate. Present results for J integrals and plastified zones are compared, respectively, with analytical solutions and available results obtained by using the body force method. The agreement between the results is found to be very good even if the truncation boundary of the finite element model is located very close to the crack tip or the plastified zone.