The interaction between the operating speed and the creep behavior of mini plastic fan has investigated in this study. The thermal-elastic-creep coupling model in Marc finite element method package are employed to simulate the stress distribution and creep deformation of a plastic fan operated in different operating temperature are simulated in this study. Results indicate that operating temperature affect the creep deformation significantly for a plastic fan or impeller. A comparison between the simulated data and measured data of PA66+ GF30 plastic fan was provided. A good agreement has been observed in this study. A comparison between the creep deformation of PET+GF30 and PBT+GF30 fan sets has also presented. Results indicate that PA66+GF30 plastic fan has a much better creep resistance a high temperature operating.

In one of the non-destructive testing techniques, Lamb waves, because of its ability to propagate a long distance and being hard to attenuate, can detect a wide range of area. However, due to its multimodal and dispersive characteristics, identifying the signals of defects during the test is often difficult. Time reversal method, a self-focusing technique, can offset the dispersion of Lamb waves and effectively focus on the spatial and temporal domain. This study applies the finite element method to stimulate the propagation of Lamb waves on an aluminum plate, selecting four sets of frequency-thickness products and two excitation types to excite the single-mode or multimode Lamb waves. This study aims to discuss the effects of modal and dispersion on the focus of the time reversal methods. The results show that 2 MHz-mm and in-plane excitation can produce numerous, more dispersive modals with the best focus effect. If we applied the time reversal method to testing the defects of Lamb waves, and the defects are circular and longitudinal notches, then, according to the results, the reflection signal amplitude of the circular defects can be highly increased. According to the test results of small-sized notches, the time reversal method cannot effectively improve the detecting ability of this defect.

A volumetric heat source finite element model is proposed to simulate the key hole effect during the Nd:YAG pulse laser welding. The measured data has been used to correlate the volumetric model parameters and the laser parameters. The laser power distributed in the beam cross area is in a Gaussian type. Two heat transfer models are employed in the fusion area, i.e the surface absorption heat transfer model in the low power intensity region and the keyhole heat transfer model in the high power intensity region. An experimentally measured critical power intensity is introduced to identify the occurrence of keyhole effect. The value of critical power intensity is dependent on the welding material. A series of MARC finite element simulations based on the proposed single pulse model are performed to investigate the feasibility and accuracy of this proposed pulse laser welding model. Different power and welding duration pulse laser have used to weld the S304L specimens. The results indicate a good agreement between the simulated and measured shape and size of the weld pool with different laser energy intensities. The validity of the proposed model is confirmed for the S304L steel. The temperature and residual stress distributions around the welding pool in a continuous pulse welding and two sheet overlap welding have also been studied by using the proposal model. The numerical results indicate that the pulse energy, duration and dwell period may affect the residual stress distribution and post-weld deformation significantly. All these results reveal that the proposed volumetric heat source finite element model is a feasible model to analyze the welding phenomena during the pulse laser welding. The results indicate that the pulse dwell period increase in dual pulse laser welding the residual stress decrease on the top of the weld spot surface. The results also show the lower residual stress in multi spots pulse laser welding with smaller weld spots center pitch and weld spot dwell period.

Wire bonding has been used in integrated circuit packaging for many decades because of its high reliability and performance. The most common metal used has been gold, but with the surge in commodity prices of gold in recent years, copper wire is now used to altered gold wire for cost saving. Many challenges have to be solved to meet its application requirement; coating is one of the applications. In this study, a 3D coated copper wire and coated Al pad is built by finite element method to simulate ultrasonic bonding and thermosonic bonding. To consider the effect of coated material to stress and strain field on ultrasonic bonding and the effect of coated material to temperature field on thermosonic bonding. Then use the Taguchi experiment method to discuss the effect on Cu-Ball and Al pad under different coated material and thickness combination. The results show that with coated material on Al pad or copper wire could reduce more than 48% of effective plastic strain after the bonding process, it obviously reduce the Al splash phenomenon in copper wire bonding. But the coated material such like palladium and nickel which have lower thermal conductivity would resist the heat transfer. And the Taguchi experiment method shows that the most effective way to reduce the effective stress during impact stage and ultrasonic vibration stage is to increase the thickness of palladium and nickel respectively, and when the thickness of coated material Au reached 0.01£gm could increase the temperature of Cu-Ball and Al pad mostly.

When an aluminum alloy plate after rolling, non-uniform residual stress distributions existed inside the plate and defects, such as edge wave, middle wave, of the plate will be induced. Usually, a levelling process will be adopted to modify the plate flatness. By numerically simulating the tension levelling process, the purpose of this thesis is to understand the final dimensions and the residual stress distribution of the aluminum plate subjected to the tension levelling process. This study used the finite element method as the basic theory of the numerical simulation. A 3-D model of a cold-rolled plate with a side wave, subjected to tension levelling process was constructed. Then, the effects of the variations of the tensile ratio and residual stress distribution after rolled on the residual stress distribution after levelling and the improvement of flatness were studied. The simulation results showed that in the wave region, the tension levelling process could eliminate more than 90% of the residual stress, in the flat region was up to 80%.Also, after leveling, the residual stress distribution in the flat region was more uniform than the wave region. After-rolled residual stresses at the wave region affected the final peak position of the wave and the stress eliminated ratio of the wave region, but showed no significant effect on the final plate width and the residual strains. After-rolled residual stresses at the flat region affected the stress elimination ratio of the flat region only. The tensile ratio would affect the plate flatness, the plate width, stress elimination ratio, and the maximum residual stress. The higher of the tensile ratio, the more flatness of the plate would be obtained, but the higher residual strain would be induced and caused the lesser range of available plate.

Textile composites have a wide variety of applications in the aerospace, sports, automobile, marine and medical industries. Due to the availability of a variety of textile architectures and numerous parameters associated with each, optimal design through extensive experimental testing is not practical. Predictive tools are needed to perform virtual experiments of various options. The focus of this research is to develop a better understanding of linear elastic response, plasticity and material damage induced nonlinear behavior and mechanics of load flow in textile composites. Textile composites exhibit multiple scales of complexity. The various textile behaviors are analyzed using a two-scale finite element modeling. A framework to allow use of a wide variety of damage initiation and growth models is proposed. Plasticity induced non-linear behavior of 2x2 braided composites is investigated using a modeling approach based on Hill’s yield function for orthotropic materials. The mechanics of load flow in textile composites is demonstrated using special non-standard postprocessing techniques that not only highlight the important details, but also transform the extensive amount of output data into comprehensible modes of behavior. The investigations show that the damage models differ from each other in terms of amount of degradation as well as the properties to be degraded under a particular failure mode. When compared with experimental data, predictions of some models match well for glass/epoxy composite whereas other’s match well for carbon/epoxy composites. However, all the models predicted very similar response when damage factors were made similar, which shows that the magnitude of damage factors are very important. Full 3D as well as equivalent tape laminate predictions lie within the range of the experimental data for a wide variety of braided composites with different material systems, which validated the plasticity analysis. Conclusions about the effect of fiber type on the degree of plasticity induced non-linearity in a ±25° braid depend on the measure of non-linearity. Investigations about the mechanics of load flow in textile composites bring new insights about the textile behavior. For example, the reasons for existence of transverse shear stress under uni-axial loading and occurrence of stress concentrations at certain locations were explained.

Overhead transmission lines are periodically inspected using both on-ground and helicopter-aided visual inspection. Factors including sun glare, cloud cover, close proximity to power lines and the rapidly changing visual circumstances make airborne inspection of power lines a particularly hazardous task. In this research, a finite element model is developed that can be used to create the theoretical dispersion curves of an overhead transmission line. The complex geometry of the overhead transmission line is the primary reason for absence of a theoretical solution to get the analytical dispersion curves. The numerical results are then verified with experimental tests using a non-contact and broadband laser detection technique. The methodology developed in this study can be further extended to a continuous monitoring system and be applied to other cable monitoring applications, such as bridge cable monitoring, which would otherwise put human inspectors at risk.

The multi-scale modeling of ion-solid interactions presented can lead to a fundamentally new approach for understanding temperature evolution and damage formation. A coupling of the Monte Carlo code, SRIM, to a C FEM heat transfer code was performed, enabling a link between the damage cascade event to the subsequent heat transfer. Modeling results indicate that for 1 MeV Ni ion irradiation in Ni52.5Nb10Zr15Ti15Pt7.5, the heat transfer rate is too large for direct crystallization. Although the damage cascade induces a peak temperature of 5300 K, within 6 picoseconds the temperature is below the glass transition temperature. This result implies that there is a cooling rate of 10^14 K/s, which is much greater than the critical cooling rate for this material. Ion irradiation was performed to compare modeling with experiment. No evidence of direct crystallization is observed under TEM. Nanocrystals are formed as a consequence of series of multistage phase transitions. This provides evidence that the energy dissipation occurs too quickly for direct crystallization, as crystals are found in regions having undergone substantial compositional changes. A host of conventional electron microscopy methods were employed to characterize the structural changes induced by 1 MeV Ni ion irradiation in Ni52.5Nb10Zr15Ti15Pt7.5 and identify the phases that form, Ni3Nb, Ni3Ti and Ni3Zr. Scanning TEM analysis revealed Pt segregation near crystal regions due to irradiation. Due to a lack of Pt crystal phases observed and high concentrations of Pt in crystal regions it is postulated that Pt is substituting for Ni to form (Ni,Pt)3Nb and (Ni,Pt)3Ti.

The tube hydroforming (THF) technology has been widely used in manufacturing the lightweight and high strength components. The success of THF is largely dependent on the selection of the loading paths: internal pressure vs. time and axial feeding vs. time. The Finite element method is used to simulate the forming result of different loading paths and reduce the cost of die-testing. T-shape tube hydroforming is investigated adaptive simulation by combining FEM code LS-DYNA with fuzzy logic controller subroutine is proposed. During the simulation process, subroutines can adjust the loading paths according to the values of the minimum tube thickness and its variance. Then, the purpose of better thickness distribution of the formed tube at the side branch is achieved. Comparing with other linear loading paths, this adaptive control method got better results. In experiments, the validity of LS-DYNA applied in THF process is verified and the experimental results by adaptive simulation are better than those by the linear loading paths.

Eddy current testing is a non-destructive testing method that has usually used for examination of carbon steel tubes. By using a high frequency electromagnetic field on the exciting probe, it is easy to figure out the impedance variation of the coil on impedance plane, and estimate the crack depth by measuring the angle of curve. However, different kind of tubes and electromagnetic properties resulted in different testing. The purpose of this study is to create the two dimensional axial symmetry model of eddy current testing by finite element software package FEMLAB. And it is easy to estimate the crack depth by figuring the impedance plane and evaluation curves by MATLAB. Furthermore, the research analyzed the variation of curves and angles on an impedance plane and tried to reduce testing errors. Over all, the analysis of some influence factors of eddy current testing in the present study not only provides a standard of estimating crack depth more accurately, but also reduces the evaluation errors.