Magnetic components are necessary for switch-mode power electronics converters, but they are often the bulkiest and heaviest in the system. Novel magnetic designs with intricate structures lead to the size reduction of power electronics converters but pose challenges to the fabrication process and material availability. Because of their low-temperature and pressure-less process-ability, magnetic pastes would be the material of choice to make magnetic cores with complex geometries. However, most magnetic pastes reported in the literature suffer from low relative permeability (µr < 26) due to the low magnetic fraction limited by viscosity. The conventional approach of developing magnetic pastes involves experimental iterations with trial-and-error efforts to determine the optimal compositions. To shorten the development cycle and take advantage of the computational power in the current age, this work focuses on exploring, validating, and demonstrating a computer-aided methodology to correlate material's processing, microstructure, and property to guide the development of magnetic pastes. The discrete element method (DEM) simulation was explored to create materials' microstructure and the finite element method (FEM) simulation was utilized to study the magnetic permeability based on the microstructure created by DEM or taken from an actual material sample. The combination of DEM and FEM provided the linkage among processing-microstructure-property relations. Then, the methodology was verified and demonstrated by improving a starting formulation. The formulation was modeled with DEM based on multiple variables, e.g., particle shape, size, size distribution, mixing ratio, gap, gap distribution, magnetic volume fraction, etc. The optimal mixing ratio of different powders to achieve the maximum magnetic fraction was determined by DEM. Experimental results confirmed the predicted optimal mixing ratio. To further take advantage of the computational tools, the magnetic permeability of the magnetic pastes was computed by FEM based on the DEM-generated microstructures. The effects of powder mixing ratio and magnetic volume fraction on the magnetic permeability were studied, respectively. Compared with the experimental values, the microstructure-based FEM simulations could predict the magnetic permeability of the formulations with varied powder mixing ratios or magnetic volume fractions with an average error of only 10 %. Another critical aspect of employing magnetic pastes for magnetic components in power electronics is capable of tailoring their magnetic permeability to meet different design needs. The methodology was further verified and demonstrated by guiding the selection of composition parameters for tailorable magnetic permeability of a starting formulation with flaky particles. An FEM model was constructed from a microstructural image and varied parameters were explored (particle permeability, matrix permeability, particle volume fraction, etc.) to tailor the magnetic permeability. To verify the simulated results, a set of magnetic pastes with various volume fractions of flakes was prepared experimentally and characterized for their permeability. Comparing the simulated and measured permeability, the error was found to be less than 10 %. Last, the guideline was demonstrated to predict a material composition to achieve a target relative permeability of 30. From the predicted composition, the magnetic paste was prepared and characterized. The error between experimental permeability and the target was only 5 %. With the guideline, one can formulate magnetic pastes with tailorable permeability with minimal experimental effort and select the composition parameters to achieve a target permeability. After developing a series of magnetic pastes with tailorable permeability and a maximum value of 35, the feasibility of making magnetic components with magnetic pastes was demonstrated. The commonly used magnetic cores – C-core, E-core, toroid core, bar core, and plate core were fabricated by a low-temperature (< 200 °C) and pressure-less molding process. Several innovative magnetic components with intricate core structures were also fabricated to demonstrate the shape-forming flexibility. The magnetic paste can also be used as the feedstock for paste-extrusion-based additive manufacturing, which further enhances the shape-forming capability. For demonstration, a multi-permeability core was fabricated by 3D printing the magnetic pastes with tailored permeability. The feasibility of making high-performance magnetic components by additive manufacturing or low-temperature pressure-less molding of magnetic pastes opens the door to power electronics researchers to explore more innovative magnetic designs to further improve the efficiency and power density of the power electronics converters. / Doctor of Philosophy / Magnetic components are necessary for switch-mode power electronics converters, but they are often the bulkiest and heaviest in the system. To reduce the size of the power converters, it is crucial to reduce the size of magnetic components by employing innovative magnetic designs. However, the complicated geometries of the novel magnetic designs pose challenges to the availability of material feedstock and the fabrication process. Magnetic pastes would be the material of choice to make magnetic components with intricate structures because of their flexibility in shape-forming with low-temperature and pressure-less processes. However, most magnetic pastes reported in the literature suffer from low magnetic permeability due to the low magnetic fraction limited by viscosity. The conventional approach of developing magnetic pastes involves experimental trial-and-error efforts to determine the optimal compositions. To shorten the development cycle and take advantage of computational power in the current age, this project focuses on exploring, validating, and demonstrating a computer-aided way to correlate material's processing, microstructure, and property relations to guide material development. The numerical simulations were explored to generate the microstructures and study the properties. With the guidance provided by computer simulations, a series of magnetic pastes with tailorable permeability was developed. Several novel magnetic components were fabricated with the as-developed magnetic pastes via molding or additive manufacturing to demonstrate the shape-forming flexibility.

京都大学 / 新制・課程博士 / 博士(理学) / 甲第24167号 / 理博第4858号 / 新制||理||1695(附属図書館) / 京都大学大学院理学研究科物理学・宇宙物理学専攻 / (主査)教授 早川 尚男, 教授 佐々 真一, 教授 山本 潤 / 学位規則第4条第1項該当 / Doctor of Science / Kyoto University / DFAM

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Indiana University-Purdue University Indianapolis (IUPUI) / A procedure for calibrating a discrete element (DE) computational soil model for various moisture contents using a conventional Asperity-Spring friction modeling technique is presented in this thesis. The procedure is based on the outcomes of two physical soil experiments: (1) Compression and (2) unconfined shear strength at various levels of normal stress and normal pre-stress. The Compression test is used to calibrate the DE soil plastic strain and elastic strain as a function of Compressive stress. To calibrate the DE inter-particle friction coefficient and adhesion stress as a function of soil plastic strain, the unconfined shear test is used. This thesis describes the experimental test devices and test procedures used to perform the physical terramechanical experiments. The calibration procedure for the DE soil model is demonstrated in this thesis using two types of soil: sand-silt (2NS Sand) and silt-clay(Fine Grain Soil) over 5 different moisture contents: 0%, 4%, 8%, 12%, and 16%. The DE based models response are then validated by comparing them to experimental pressure-sinkage results for circular disks and cones for those two types of soil over 5 different moisture contents. The Mean Absolute Percentage Error (MAPE) during the compression calibration was 26.9% whereas during the unconfined shear calibration, the MAPE was calculated to be 11.38%. Hence, the overall MAPE was calculated to be 19.34% for the entire calibration phase.

Fluidized beds have widespread industrial applications ranging from chemical industries to power plants. The flow inside a fluidized bed system consists of two main phases, a particle phase and the fluid phase. The two phases are strongly coupled to each other through various forces like drag and pressure. Capturing this multiphase phenomenon requires modeling strategies that possess good fidelity over a range of scales. Discrete Element Modeling (DEM) coupled with Computational Fluid Dynamics (CFD) provides a good platform to analyze the complex coupled multiphase hydrodynamics inside fluidized bed systems. Conventional DEM-CFD framework suffers from contradictory spatial resolution requirements for the particle and fluid phases, respectively. This prevents the conventional DEM-CFD method to be applied to geometries that have features comparable to the particle diameter of the solid phase. The novelty of this work lies in the development and validation of a two-grid formulation that removes the resolution restrictions of the conventional DEM-CFD framework. The results obtained from this new framework agree reasonably well with the experiments showing the capability of the new scheme to simulate conditions not possible with conventional DEM-CFD framework. In addition, this research also focuses on performing both 2D and 3D jetting fluidized bed simulations having millions of particles; validate/compare results with experiments and to perform heat transfer studies in a jetting fluidized bed system. The results suggest convective and diffusive mixing for a single jet at higher superficial velocity to be better than the mixing obtained in a multiple jet framework. The comparison with experimental results obtained in a multiple jetting setup shows that a 2D simulation captures the essential jet characteristics near the distributor plate reasonably well while a 3D simulation is needed to capture proper bubble dynamics near the freeboard of the bed. These results give insight into the detailed dynamics of fluidized bed systems and provide a foundation for a better design of these systems. / Ph. D.

Yes / Numerical simulation of wet granulation in a continuous granulator is carried out using Discrete Element Method (DEM) to discover the possibility of formation of seeded granules in a continuous process with the aim of reducing number of experimental trials and means of process control. Simple and scooped drum granulators are utilized to attain homogenous seeded granules in which the effects of drum rotational speed, particles surface energy, and particles size ratio are investigated. To reduce the simulation time a scale-up scheme is designed in which a dimensionless number (Cohesion number) is defined based on the work of cohesion and gravitational potential energy of the particles. Also a mathematical/numerical method along with a MATLAB code is developed by which the percentage of surface coverage of each granule is predicted precisely. The results show that use of continuous granulator is promising provided that a high level of shear is considered in the granulator design, e.g. it is observed that using baffles inside the drum granulators is essential for producing seeded granules. It is observed, moreover, that the optimum surface energy for scooped granulator with rotational speed of 50 rpm is 3 J/m2 which is close to the number predicted by Cohesion number. It is also shown that increasing the seed/fine size ratio enhances the seeded granulation both quantitatively (60% increase in seeds surface coverage) and qualitatively (more homogeneous granules).

Compressive residual stresses (CRS) are beneficial for enhancing the fatigue life of metal components. Shot Peening (SP) is an industrial cold working process that is applied to induce a field of CRS and modify the mechanical properties of the metal component. The SP process involves impacting a surface with tiny shots with forces sufficient to create plastic deformation. The process is governed by a number of important parameters such as the shot size, angle of attack, initial velocity, mass flow rate and the distance from the shot nozzle to the surface being peened. The relationship between the optimal peening outcome, particularly the residual stress distribution of the treated surface, and the peening parameters is still unknown and needs to be investigated further. Manufacturers are interested in producing a uniform peening process for complex geometries which optimises the SP parameters. Modelling the process is complex as it involves the interaction of a metallic surface with a large number of shots of very small diameter. Conventionally, such problems are solved using finite element software to predict stresses and strains of a single shot impact then applying superposition. At the moment there are no Finite Element Method (FEM) modelling solutions involving more than tens of shots. The number of shots and elements required for such a modelling process made the approach unfeasible prior to the work described herein. The objective of this work is to develop an appropriate numerical modelling approach that can better simulate the real SP process. The model will be provided by combining Discrete Element Method (DEM) with FEM. The DEM is employed to get a distribution of impact velocities over space and time which are then implemented into a FEM analysis. A discrete element model with randomly distributed steel shots bombarding a steel component at various velocities has been developed as benchmark example. With this model the SP shot - shot interaction, the shot - target interaction, the surface coverage, angle of impingement, shot size, impact velocity and the overall shot flow can be parametrically studied in details and with little computational effort. The novel approach also proposes a new method to dynamically change the coefficient of restitution for repeated impacts during the simulation and predicts the CRS more effectively. The effects of SP on different materials of relevance to gas turbine engine components will be investigated in order to improve the understanding of the interaction between the shots and the targeted material. Initially, an uncoupled analysis was peforned, in order to assess the capabilities of the two modelling systems, DEM and FEM, to delivery an improved solutuion when combining two commercially available codes. This parametric analysis is performed using the state-of-the-art Discrete Element (DE) application EDEM. In the subsequent part of this work, a dynamic Finite Element (FE) application Abaqus will be used to investigate single shot impacts and to obtain the residual stress distribution. This gives us a prescribed residual stress distribution and peening coverage. A Combined DEM/FEM tool (DEST) is proposed that eliminates any manual pre-processing required for linking/coupling, eliminating the use of two different applications and provide an integrated solution for the simulation of the Shot Peening process. In the subsequent chapter, the implementation of essential tools for the enchanced modelling of Shot Peening process functionalities, such as the nozzle, bounding box, coverage and intensity is described. A number of computational improvements are also implemented to reduce the computation time. The existing binary search is enhanced to self-balancing search tree and further improved to allow insertion and deletion of elements. A bounding box feature which removes shots that move out of the domain during the course of the simulation is also implemented. Experiments featuring single shot impacts are performed to gain better understanding the deformation process in the target material subjected to impact conditions to those occurring in the production peening. The single shot impacts are experimentally examined using SEM and EBSD. During final chapter, case studies are performed to compare the results of the simulations with large-scale experimental work. The coverage of peening of single and multiple nozzles with different angle of impingements are assessed. Finally, possible directions for further research concerning the accurate quantification of material responses to SP are identified in the report.

Dans cette thèse, nous avons étudié la simulation numérique des phénomènes d'interaction fluide-structure entre un fluide compressible et une structure déformable. En particulier, nous nous sommes intéressés au couplage par une approche partitionnée entre une méthode de Volumes Finis pour résoudre les équations de la mécanique des fluides compressibles et une méthode d'Eléments discrets pour le solide, capable de prendre en compte la fissuration. La revue des méthodes existantes de domaines fictifs ainsi que des algorithmes partitionnés couramment utilisés pour le couplage conduit à choisir une méthode de frontières immergées conservative et un schéma de couplage explicite. Il est établi que la méthode d'Eléments Discrets utilisée permet de retrouver le comportement macroscopique du matériau et que le schéma symplectique employé assure la préservation de l'énergie du solide. Puis nous avons développé un algorithme de couplage explicite entre un fluide compressible non-visqueux et un solide indéformable. Nous avons montré des propriétés de conservation exacte de masse, de quantité de mouvement et d'énergie du système ainsi que de consistance du schéma de couplage. Cet algorithme a été étendu au couplage avec un solide déformable, sous la forme d'un schéma semi-implicite. Cette méthode a été appliquée à l'étude de problèmes d'écoulements non-visqueux autour de structures mobiles : les comparaisons avec des résultats numériques et expérimentaux existants démontrent la très bonne précision de notre méthode / This work aims at the numerical simulation of compressible fluid/deformable structure interactions. In particular, we have developed a partitioned coupling algorithm between a Finite Volume method for the compressible fluid and a Discrete Element method capable of taking into account fractures in the solid. A survey of existing fictitious domain methods and partitioned algorithms has led to choose an Embedded Boundary method and an explicit coupling scheme. We first showed that the Discrete Element method used for the solid yielded the correct macroscopic behaviour and that the symplectic time-integration scheme ensured the preservation of energy. We then developed an explicit coupling algorithm between a compressible inviscid fluid and an undeformable solid. Mass, momentum and energy conservation and consistency properties were proved for the coupling scheme. The algorithm was then extended to the coupling with a deformable solid, in the form of a semi-implicit scheme. Finally, we applied this method to unsteady inviscid flows around moving structures: comparisons with existing numerical and experimental results demonstrate the excellent accuracy of our method

La déchirure musculaire est la première cause de blessure chez les athlètes. De nombreuses études décrivent ce traumatisme musculaire sans parvenir à en identifier clairement la chronologie et ses circonstances. L’objectif de la thèse est de décrire le phénomène de déchirure musculaire avec la méthode des éléments discrets, en s’appuyant sur des essais expérimentaux pour valider les modèles numériques. Dans une première partie, une revue de littérature permet d’acquérir les propriétés mécaniques des différents éléments constituant le complexe musculo-tendineux afin de pouvoir en réaliser un modèle macroscopique. Dans une deuxième partie, la modélisation du complexe musculo-tendineux est réalisée. La validation du comportement mécanique en traction passive du modèle proposé est réalisée en comparaison des travaux de L-L. Gras sur le muscle sternocléidomastoïdien humain. L’influence des paramètres morphologiques sur le comportement mécanique global est ensuite étudiée. La rupture fait l’objet de la troisième partie. Une modélisation de l’ensemble {tendon d’Achille/triceps sural} est réalisée et soumise à un test de traction passif jusqu’à rupture. La validation des résultats est faite vis-à-vis des essais expérimentaux réalisés sur cet ensemble musculaire provenant de pièces anatomiques humaines. L’étape suivante s’attache à modéliser la contraction musculaire, implémentée au niveau des fibres musculaires. Une validation du comportement actif du complexe musculo-tendineux est réalisée. Cette dernière étape, combinée à la traction destructive permet d’étudier la faisabilité de modéliser la déchirure par la méthode des éléments discrets, mais également d’étudier les structures endommagées et les mécanismes de rupture. Cela ouvre des possibilités d’utilisation cliniques de ce modèle pour comprendre et prévenir des blessures par déchirure musculaire. / Tearing of the muscle-tendon complex is a common sport-related injury for athletes. Many studies reported description of this traumatism but mechanisms leading to such an injury are still unclear as are the site of mechanical failure and involved structures. The aim of the thesis is to describe the phenomenon of the muscle-tendon-complex’s tear using the discrete element method and validating the numerical model with experimental data. In the first part, a literature review explains the different properties of the muscle-tendon complex main components’ in order to model it at the macroscopic scale. In the second part, the muscle-tendon complex is modeled. Validation of the mechanical behavior in passive tensile test is proposed by comparison with experimental data from L.-L. Gras on human sternocleidomastodeus muscle. Then, the different influences of morphometric parameters on the mechanical behavior of the complex are investigated. The third part focuses on the rupture. A model of the complex set of {Achilles tendon/surae triceps} is built and a tensile test until rupture is applied. Model validity is assessed by comparison with in vitro experiments from human cadavers. The fourth part focuses on the muscular activation, implemented inside fibers’ behavior. Validity of its active behavior is investigated. This fifth and last presents the enrichment with destructive tensile test. This added test allows first to study the feasibility to model the tear with the discrete element method; and second to focus on damaged structures and rupture’s mechanisms. This offers possibilities for clinical applications of this model to understand and prevent injuries caused by a tear of the muscle-tendon complex