No description available.

The objective of this work is to develop an evolution equation for the ductile growth of a spherical void in a highly strain rate and temperature dependent material. The material considered in this work is stainless steel 304L at 982 °C. The material is characterized by a physically-based internal state variable model derived within consistent kinematics and thermodynamics — Evolving Microstructure Model for Inelasticity. Through this formulation, the degradation of the elastic moduli due to damage has been naturally acquired. An elastoviscoplasticity user material subroutine has also been developed and implemented into a commercially available finite element software ABAQUS. The subroutine utilizes a return mapping algorithm, where a purely elastic trial state (elastic predictor) is followed by a plastic corrector phase (return mapping). A conditionally stable fully-implicit scheme, derived from the backward Euler integration method, has been employed to calculate the values of the internal state variables in the elastoviscoplasticity integration routine. A repeating unit cell problem is set up by introducing a spherical void inside a matrix material that simulates a periodic array of voids in a component. Using finite element analysis, a database is generated by recording the responses of the unit cell under various combinations of loading conditions, porosity, and state variables. Functional forms of the void growth equations are constructed by utilizing normalization techniques to collapse all the data into master curves. The evolution equations are converted to a form consistent with the continuum damage variable in the complete thermal-elastic-plastic-damage version of the physically-based internal state variable model.

Rutting failures are prominent in expedient airfields constructed with AM2 landing mats over soft existing subgrades. There are many issues that must be addressed when approaching this multiaceted problem. The load transfer mechanism occurring at interlocking mat joints and the mat-soil interface bonding condition affect near surface subgrade response. The repeated loading coupled with lateral aircraft wander causes significant principal stress rotation in the subgrade. This kneading action then causes variations in the excess pore-water pressure and a subsequent softening of the soil. The purpose of this study is to investigate the critical factors that lead to subgrade rutting failures in landing mats constructed over soft subgrades. A three dimensional finite element (3D FE) model of a landing mat system over soft subgrade is implemented under both static and pseudo-dynamic loading conditions with aircraft wander. To capture the complex stress histories induced by the simulated moving gear loads over the unique structural features of the AM2 mat system, an elastoplastic kinematic hardening constitutive model, the Multi-Mechanical Model, is developed, calibrated and used to represent the subgrade response. Under both static and pseudo-dynamic loading, the FE model results match very well with the stress and deformation results from full-scale instrumented testing of the AM2 mat over 6 CBR subgrade. Results show that incorporating the load transfer mechanism occurring at the mat joints and varying the mat-soil interface condition affect the near surface subgrade deformation and stress responses that contribute to rutting failures. Furthermore, rotation of the principal stress axes and changes in excess pore-water pressures occur in the subgrade because of the moving tire load. These phenomena contribute to extension of the field of deformation influence around the trafficked area in the subgrade and upheaval at the edges of the test section. Findings of this study show that although layered elastic analysis procedures are the basis of current airfield design methodologies, critical design features and the corresponding deformation responses can be better modeled using the FE approach. Furthermore, the proposed 3D modeling approach implementing aircraft wander can provide a reliable platform for accurately simulating the subgrade response under pseudo-dynamic loading conditions.

In this study, the teeth of the Carcharodon carcharias (Great White) and the Galeocerdo cuvier (Tiger) sharks were analyzed to examine their optimized structure-property relationships and edge serrations with regards to shearing. Structure-property analysis was conducted using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy, X-ray diffraction, and optical microscopy to study the teeth using parametric optimization. Quantifying the structural properties also focused on the tooth serrations, which were captured in SEM and micrographs and were analyzed for geometric parameters using ImageJ software. Nanoindentation was performed to determine the material's mechanical properties. Further, finite element analysis (FEA) of the sharks' teeth serrations were carried out to quantify the optimum shearing performance of each serration type – zeroth (no serrations), first (a single array of serrations), and second (a secondary array of serrations upon the first array) order serration. Here, serration order, bite velocity, and angle-of-impact for ascertaining sharks' teeth shearing performance were analyzed. FEA results showed that serrated edges reduced the energy required to pierce and shear materials as the angle of penetration moved away from perpendicular to the surface. These bioinspired findings will help advance the design and optimization of engineered cutting tools.

This thesis presents the development and implementation of a generalized optimization framework for use in sheet-stamping process simulation by finite element analysis. The generic framework consists of three main elements: a process simulation program, an optimization code, and a response filtering program. These elements can be filled by any combination of applicable software packages. Example sheet-stamping process simulations are presented to demonstrate the usage of the framework in various forming scenarios. Each of the example simulations is presented with a sensitivity analysis. These examples include analysis of a 2-dimensional single-stage forming, a 2-dimensional multi-stage forming, and two different 3-dimensional single-stage forming processes. A forming limit diagram is used to define failure in the 3-dimensional process simulations. Optimization results are presented using damage minimization, thinning minimization, and springback minimization with aluminum alloy 6061-T6 blanks.

A study has been conducted to compare conventional pavements and perpetual pavements with a particular emphasis on perpetual pavements. One of the main drawbacks of conventional pavements and motivations for this work is the maintenance required for hot mix asphalt (HMA) pavements with sub-drainage systems. Perpetual pavements, as the name suggests, are designed with a long life. However, this is a relatively new concept and there are still many unknowns concerning their performance. This dissertation was written to answer some of the questions. The study examines structural response and performance of perpetual pavements. Also, deterioration and performance of perpetual pavements will be contrasted to conventional pavements. Empirical data from the National Center of Asphalt Technology (NCAT) Test Track study was obtained, analyzed and used as a basis for evaluating theoretical models. Computational models for both conventional and perpetual pavements were constructed and analyzed using the general purpose finite element analysis software ABAQUS. Geometry, materials and loading are modeled with sufficient accuracy. This research examined several types of responses of perpetual pavements. It extends the traditional criteria of pavement distress by suggesting that longitudinal strain at the surface of a pavement HMA layer as an important criterion. Shear strain was studied and it provides a reasonable explanation of some distresses in pavements. By studying the FEA results from conventional and perpetual pavements and a thorough investigation of the thickness effects, it provides some rationale on why strain at the top of thick pavements is critical. The effects of dynamic wheel loadings are presented. Finally, the effect of environment, specifically temperature and moisture, on perpetual pavements are studied.

The overall goal of this work is to predict the mechanical response of an as-built Ti-6Al-4V directed energy deposition component by a dislocation mechanics-based internal state variable model based on the component's geometry and processing parameters. Previous research has been performed to connect additive manufacturing (AM) process parameters including laser power and scanning strategy to different aspects of part quality, such as porosity, mechanical properties, fatigue life, microstructure, residual stresses, and distortion. The lack of predictive capabilities to fully estimate residual stresses and distortion within parts produced via AM have hindered part qualification; however, modeling the AM process can aide in process and geometry optimization compared to traditional trial-and-error methods. The presence of unwanted thermally induced residual stresses and distortion can lead to tolerancing issues, reduced fatigue life, and decreased mechanical performance compared to similar components fabricated with traditional manufacturing methods such as casting and machining. A three-dimensional thermomechanical finite element model calibrated using dual-wave pyrometer thermal image datasets along with temperature- and strain rate-dependent mechanical data is utilized for this work. The purpose of this work is to understand the relationship between a component's temperature history and its resultant distortion and residual stresses.

Sensor technology has played an essential role in improving the observability in manufacturing processes and providing input to enabling more effective and efficient product and process design. To analyze an injection molding process, pressure and temperature variations have shown to be the most critical factors that affect quality in the molded parts. The state of sensing in the industry utilizes separate and wired sensors placed away from the mold cavity to measure these parameters, and holes have to be drilled through the mold steel to accommodate the wires. To minimize mold structural modification, which is time consuming and expensive, it is desired to design a miniaturized sensor module that can be structurally embedded into the molding cavity and simultaneously measures the two parameters (i.e. a dual-parameter sensor) in real time, during the molding process. This thesis presents the structural optimization of the sensor and development of a new Fluid-Structure algorithm to analyze the performance of the sensor as in an actual injection molding cycle. Thus, research involves three key tasks. Given a required mold steel thickness, an optimization problem was solved analytically with outer diameter, thickness and number of rings as variables under the maximum allowable pressure and minimum required energy constraints to achieve a minimum volume of the piezo stack. As it is infeasible to test the sensor with different dimensions under the flow to understand its behavior under high pressure and temperature polymer melt, the development of a numerical model is required. A mold-melt interaction algorithm is developed to have a mold-melt interface using finite element analysis, analogous to an injection molding process. The model showed the change in state of polymer melt and its effect on cavity due to change in viscosity with the change in temperature. The model validated the energy output of the optimized sensor when the temperature and pressure of polymer changes and the effect of these parameters on mold and sensor. The voltage output and temperature results were compared with analytical solution. The numerical results of voltage output matched within 0.1% and temperature results matched within 3% of the analytical solutions. Finally a test bed was fabricated to simulate and reconstruct the pressure profile obtained from the numerical model to study the actual output from a fabricated sensor. The aim of the test bed was to reconstruct pressure profiles obtained from numerical simulations to investigate the sensor output from the fabricated injection molding sensor. The test bed evaluated the output from sensor as can be observed in actual injection molding machine. Comparison of the injection molding sensor with a piezo-resistive sensor showed good agreement.

No description available.

No description available.