Modeling of friction-stir butt-welds and its application in automotive bumper impact performance Part 1. Thermo-mechanical weld process modeling

The demand for better structural performance in joining of components for road vehicles prompts the implementation of aluminum alloy friction stir welding technology in the automotive industry. The aim of current study is the creation of a 3-D finite element (FE) friction thermal model and stir welding (FSW) process of dissimilar aluminum alloy and for the estimation of crash worthiness performance of FSW fabricated shock absorber assembly. Thermo mechanical simulations and analysis are performed to understand the thermal behavior in the FSW weld zones. The developed models are correlated against published experimental results in terms of temperature profile of the weld zone. The developed models are then implemented for fabricating vehicle bumper parts to illustrate the performance of FSW welded components during an impact. Customary sled testing for low-speed guard necessities is performed utilizing a grating blend welded test apparatus at Wichita State University (WSU) at the National Institute for Aviation Research (NIAR). A few guard congregations are then appended to the test installation utilizing FSW and conventional Gas bend GMAW welding strategies. Numerical models are likewise created where limited component investigation is utilized to contrast the anticipated harm and the real harm maintained by both of the FSW and GMAW manufactured guards. During the research, a new FSW weld mold is created that allows for a better representation of the desired progressive crack propagation. The FSW fabricated bumper based on the Johnson-Cook failure model yields better failure prediction and is in good agreement to the test. The results from this study provide a guideline for an accurate finite element modeling of a FSW fabricated components and their application in the crashworthiness of such structural components.     

Adaptive control of a vehicle-seat-human coupled model using quasi-zero-stiffness vibration isolator as seat suspension

We propose the quasi-zero-stiffness (QZS) vibration isolator as seat suspension to improve vehicle vibration isolation performance. The QZS vibration isolator is composed of vertical spring and two symmetric negative stiffness structures used as stiffness correctors. A vehicle-seat-human coupled model considering the QZS vibration isolator is established as a three degree-of-freedom (DOF) model; it is composed of a quarter car model and a simplified 1 DOF model combined vehicle seat and human body. This model considers the changing mass of the passengers and sets the total mass of the vehicle seat and human body as an uncertain parameter, which investigates the overload and unload conditions in practical engineering. To further improve the vehicle ride comfort, a constrained adaptive backstepping controller law based on the barrier Lyapunov function (BLF) is presented. The dynamic characteristic of the active vehicle-seathuman coupled model under shock excitation was analyzed using numerical method. The results show that the designed controller law can isolate the shock excitation transmitted from the road to the passengers effectively, and both the vehicle and seat suspension strokes remain in the allowed stroke range.     

Fault diagnosis of an automobile cylinder head using low frequency vibrational data

This paper proposes a vibration-based fault-diagnosis method for mechanical parts. This method, after algorithm development, only requires a single inexpensive test to inspect the part which could take as short as half a second. The algorithm is developed in three major stages, (i) exciting specimens without or with known faults using a controlled force and recording acceleration of a single point for a short time (ii) finding a signature for each faulty specimen, using Fourier transform and statistical analysis. (iii) Developing a multi-layer perceptron, as a mathematical model, using the results of stage (ii). The elements of a part signature are the inputs to the model. The location (and possibly size and shape factor) of the fault is model output. Stage (i) can be performed experimentally or alternatively with a validated FEM, one experiment or simulation per specimen. The proposed technique was examined to locate (isolate) a fault on an automobile cylinder head. The presented accuracy is considerable, and the data collected at fairly low frequency range (below 1200 Hz) were found to be sufficient for this technique. In the case study of this paper, possible fault locations are on a line; as a result, fault location has one dimension. It is shown that the technique can be extended to higher dimensions.     

Dynamic analysis of the wind turbine drivetrain considering shaft bending effect

In the previous research, shaft torsional flexibility was only considered in the wind turbine drivetrain. However, if shaft is longer and thinner than other parts, two components which are connected by shaft affect each other by rotation about bending axis. It means that there are deflections of shaft about not only torsional direction but also bending direction. In this research, we introduced spherical joint which have 3 spring stiffness about all rotational axis to define shaft. And we analyzed that how shaft bending affect drivetrain rotation, translation motion and gear mesh contact force. To do these processes, we simulated the 3-dimensional wind turbine drive train model which has bearing stiffness, gear mesh stiffness, and shaft flexibility. The gear mesh stiffness was defined by Fourier series. And the equation of motion was acquired by Lagrange equation and kinematical constraints to represent shaft flexibility. About numerical analysis, the Newmark method was used to get results. Lastly, fast Fourier transform which converts results from time domain to frequency was used.     

Model-based analysis and fault diagnosis of a compound planetary gear set with damaged sun gear

The vibration properties of compound planetary gears are more complicated than that of simple ones. This paper aims to investigate the fault properties of a compound planetary gear set in chipped sun gear conditions using model-based method. A three-dimensional lumped-parameter nonlinear dynamic model for the compound planetary gear set is established. This model considers the time-varying mesh stiffness (TVMS), the mesh phase relations, and gear chipping defects. The analytical equations are derived to quantify the TVMS reduction induced by the chipped gear based on the improved potential energy method. Further, the simulations are performed to demonstrate the fault features of sun gears with single or multiple chipped teeth in different gear stages. Moreover, the theoretical derivations are validated through the experimental signals analysis.     

A methodology for determining the true stress-strain curve of SA-508 low alloy steel from a tensile test with finite element analysis

The true stress-strain curve of a material should be determined for plastic property input to numerical analysis. This study proposes a simple methodology for determining the true stress-strain curve of SA-508 Grade 3 Class 1 low alloy steel using limited information from a general tensile test with finite element analysis. Measured engineering stresses and strains can be reasonably converted to true stresses and strains under uniform deformation before necking. True stress-strains are difficult to determine after necking because of nonuniform deformation without specialized measurement techniques. Five post-necking strain hardening models are considered, namely, linear, swift, Ludwick, Hollomon-linear (HL) and Hollomon-linear-constant (HLC) models. The equations for each model can be determined using the results of the tensile test, which include the true stress-strain value at the maximum load point and the corrected true stress-strain value at the fracture point plus the Considere instability criterion. The HL and HLC models suggested that the engineering stress-strains from the finite element analysis are consistent with the experimental results.     

Pre-strain effect of on fracture performance of high-strength steel welds

Fracture toughness of pre-strain effect was determined as a function of the temperature in structural steels of the 600 to 780 MPa class. Cyclic loading during earthquakes produces pre-strain in the component, which is enhanced at the region of strain concentration. During the Kobe Great Earthquake in 1995 in Japan, 10 to 15 % pre-strain was recorded at the beam-to-column connection. The relationship between critical CTOD and CGHAZ length was sampled by fatigue pre-crack for pre-strained HAZ, which is a significant decrease compared to that of the base metal. Furthermore, the effect of pre-strain is discussed in terms of the CTOD and Charpy impact energy of the local brittle zone.     

Design and experimental analysis of new industrial vibration dampers

Vibration dampers are the first line of defense against shock and impacts sustained by mechanical and structural systems. Consequently, for decades, new impact damping technologies have been developed and applied in several engineering fields to attenuate undesired vibrations. Linear particle chain (LPC) impact dampers are the latest category of impact dampers being developed for the mitigation of unwanted vibrations in many systems. However, the challenges associated with prototyping such devices made their application in practical systems very limited. This paper proposes five innovative designs for the LPC impact dampers satisfying a wide range of industry needs in terms of efficiency, cost, and sustainability. The proposed designs are fabricated and tested under the same conditions to assess their efficiency in attenuating the vibration of a simple structure. Each design showed consistent behavior, but some designs outperformed others depending on the geometry, physical characteristics, and type of structure. The detailed design, experimental study, and time response comparisons are presented here to provide an initial study towards the development of practical sustainable LPC vibration dampers for real engineering applications.     

Numerical analysis of wave energy dissipation by damping treatments in a plate with acoustic black holes

The reduction of vibration by acoustic black holes (ABHs) with damping treatments can be achieved in two stages: energy focalization and energy dissipation. The energy focalization is mainly due to changes of the local thickness by slowing down the flexural wave speed and energy dissipation can be achieved by using viscoelastic damping materials. In structures with embedded ABHs, the damping effectiveness can depend significantly on the types of damping treatments. In this paper, 4 different damping treatments according to the types of attached region are considered in order to estimate the effectiveness of damping treatments as 1) a fully-covered unconstrained damping treatment, 2) a fully-covered constrained damping treatment, 3) a partially-covered unconstrained damping treatment and 4) a partially- covered constrained damping treatment as well as no damping treatment as reference data. In this study, the performance of damping treatments is explored using numerical simulations of three-dimensional thin plate embedded truncated ABH(s). The wave energy in the ABH, the normalized total energy and the focalization ratio are introduced to compare the effectiveness of the damping treatments. The numerical results show that the fully-covered constrained damping treatment provides the most effective configuration in terms of the wave energy in ABH and the normalized total energy.