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.

<p dir="ltr">Precise measurement of the flowrate is crucial for both process control and energy consumption evaluation. The main aim of this work is to develop a methodology to calibrate mechanical flowmeters, designed to measure high viscosity fluids, in water. In order to accomplish this, a series of computational fluid dynamics (CFD) analysis are carried out to determine how the motion of the mechanical component varies with different flow rates of water and high viscosity fluids. This data is recorded and analyzed to develop calibration curves that relate the motion of the mechanical component the flow rates. From the calibration curves, it can be determined the required water flow rate to achieve the equivalent motion of the mechanical component in a specified viscosity. This method provides an efficient and cost-effective calibration process because it eliminates the need for calibrating using heated engine oil to achieve the fluid viscosity of the flow meter is designed. Flowmeter sensitivity analysis was also performed and it was observed that the motion of the mechanical component curves converges as the size of the flowmeter increases suggesting that the effect of viscosity on flowmeter sensitivity decreases as the size of the flowmeter is increased, likely due to reduced resistance to flow and smaller pressure drops. </p><p dir="ltr">The Kanbara Reactor ladle is a commonly used method in the steelmaking industry for hot-metal desulfurization pre-treatment. The impeller's configuration is pivotal to the reactor's performance, yet its precise function remains partially understood. This study introduces a 3-dimensional Volume-of-Fluid (VOF) model integrated with the sliding mesh technique, investigating the influence of five different impeller speeds. After Validating the model through experimental data, this numerical model is applied to investigate the typical developmental phenomena and the consequences of impeller speed variations on fluid flow characteristics, interface profile, and vortex core depth. The findings reveal that the rotational impeller induces a double-recirculation flow pattern in the axial direction due to the centrifugal discharging flow. With increasing impeller rotation speed, the vortex core depth also rises, emphasizing the substantial impact of impeller speed on vortex core depth.</p>

This thesis deals with determination of effect of wing flexibility on load distribution. FSI analysis using modal superposition was used for determination of effect of wing flexibility. Analysis was verified by analytic calculation. Differences of load distribution, between rigid and flexible wing, was determined for the selected flight regimes. Change of the bending moment was up to 3,9 %. Thesis shows importance of including effect of wing flexibility for sailplane design.

Předložená diplomová práce se zabývá interakcí mezi proudící krví a krční tepnou, obsahující aterosklerotický plat, za pomoci konečnoprvkové fluid-structure interaction analýzy. První část práce obsahuje souhrn teoretických poznatků, sestávající z kardiovaskulárního systému, cév, souvisejících konstitutivních modelů, reologie krve a úvodu do teorie proudění. Dále je v práci obsažen stručný souhrn současného poznání výpočtového modelování v této oblasti, s důrazem na strukturní a fluid-structure interaction analýzy v oblasti krční tepny, a na použité konstitutivní modely. Experimentální část se soustředí na tvorbu zjednodušeného modelu krční tepny, obsahující aterosklerotický plat, a na tvorbu odpovídajícího modelu krve. Oba modely poté společně vstupují do fluid-structure interaction analýzy, která si klade za cíl pochopit důsledky pulzujícího toku krve na stěnu tepny a na růst aterosklerotického plátu; primárními zkoumanými veličinami jsou první hlavní napětí na stěně tepny, celková deformace stěny tepny, časově zprůměrovaná hodnota smykového napětí na stěně tepny a oscilační smykový index. Všechny výsledky jsou porovnány napříč několika typy analýz, tak aby bylo možné zhodnotit rozdíly a důsledky zvoleného přístupu. Součástí práce je také zjednodušená parametrická studie, která porovnává vliv rostoucího procenta stenózy na vyhodnocované veličiny. V poslední částí práce jsou zhodnoceny výsledky, její limitace a další možnosti výzkumu v této oblasti.

<p><a href="">This work investigates the effect of surface features such as roughness, pits, and cracks on the tribological and fatigue behavior of machine components. It comprises of three main investigations: (i) effect of roughness on non-contacting fatigue, (ii) lubricated contact fluid structure interaction (FSI) behavior in presence of surface cracks, and (iii) the equivalence between non-contacting and contacting fatigue and the effect of roughness.</a></p><p>For the first investigation, a novel microstructure-based approach was developed to model surface roughness. It used a finite element fatigue damage model to predict the effects of roughness on tensile fatigue. AISI 4130 steel specimens with different surface finishes were fabricated and tested in axial fatigue using an MTS machine. The experimental results demonstrated the detrimental effect of roughness on fatigue lives, which was predicted by the model accurately.</p><p>In the second investigation, a partitioned CFD-FEM based FSI solver was developed using Ansys Multiphysics software to model and investigate elastohydrodynamically lubricated contacts typical in gears and cylindrical roller bearings. The FSI model relaxes Reynolds assumptions, and uses Navier-Stokes equations to determine the lubricant flow and utilizes finite element method to model the structural response. The FSI model was evaluated for robustness under various operating conditions. The effect of material plasticity, subsurface features, etc. were also investigated. The model was then extended to investigate the effects of surface cracks in rolling/sliding EHL line contacts. Using CFD based approach enabled the investigation of surface cracks with inclined geometries, overcoming the limitations of standard Reynolds-based solvers. The effects of crack geometry parameters such as crack location, crack length, crack width, crack tip radius and crack orientation on fluid pressure distribution were studied. This investigation identified the crack geometries that affect the contact fatigue behavior by predicting the location and severity of stress concentrations in the material.</p><p>Finally, the relationship between contacting fatigue and non-contacting fatigue was investigated. A test rig was designed and developed to simulate rolling contact fatigue (RCF) surface damage. Experimental investigation revealed that the RCF surface damage stress-life (SN) results can be predicted using torsional fatigue results 10 times faster. A computational contact mechanics model was developed to incorporate the effect of roughness in this prediction, and corroborated against experimental RCF results at different roughness levels.</p>

The interaction between fluids and structures, which is an interdisciplinary problem, has gained importance in a wide range of scientific and engineering applications. Thanks to new advances in computer technology, the numerical analysis of multiphysics phenomena has aroused growing interest. Fluid-structure interactions have been numerically and experimentally studied by many researchers and published by several books, papers, and review papers. Hou et al. (2012) [3] have also published a review paper entitled “Numerical methods for fluid-structure interaction”, which provides useful knowledge about different approaches for FSI analysis. The key challenge encountered in any numerical FSI analysis is the coupling between the two independent domains with clear distinctions. For example, a structure domain requires discretizing by a Lagrangian mesh where the mesh is fixed to the mass and follows the mass motion. In fact, the Lagrangian mesh is able to deform and follows an individual structural mass as it moves through space and time. Nonetheless, the fluid mesh remains intact within the space, where the fluid flows as time passes. The numerical approaches with regard to FSI phenomena can be divided into two main categories, namely the monolithic approach and the partitioned approach. In the former, a single system equation for the whole problem is solved simultaneously by a unified algorithm; however, in the latter, the fluid and the structure are discretized with their proper mesh and solved separately by different numerical algorithms. When a fluid flow interacts with a structure, the pressure load arising from the fluid flow is exerted on the structure, followed by deformations, stresses, and strains of the structure. Depending on the resulting deformation and the rate of the variations, a one-way or two-way coupling analysis can be conducted. Fluid-structure interaction (FSI) is characterized by the interaction of some movable or deformable structure with an internal or surrounding fluid flow. In a fluid-structure interaction (FSI), the laws that describe fluid dynamics and structural mechanics are coupled. There is also another classification for FSI problems on the basis of mesh methods: conforming methods and non-conforming methods. In the first method, the interface condition is regarded as a physical boundary (interface boundary) moving during the solution time, which imposes the mesh for the fluid domain to be updated in conformity with the new position for the interface. In contrast, the implementation of the second method eliminates a need for the fluid mesh update on the account of the fact that the interface requirement is enforced by constraints on the system equations instead of the physical boundary motion. In this work, we study numerically and experimentally the fluid-structure interaction comprising a flexible slender shaped structure, free surface flow and potentially interacting rigid structures, categorized in flood protection applications, whereas more emphasis is given to numerical analysis. Objectives of this study are defined in detail as follows: The initial aim is the numerical analysis of the behavior of a down-scale membrane loaded by hydrostatic pressures, where the numerical results have to be validated against available experimental data. A further case which has to be investigated is how the full scale flexible flood barrier behaves when approached and impacted by an accelerated massive flotsam. The numerical model has to be built so as to replicate the same physical phenomenon investigated experimentally. It enables a comparison between the numerical and experimental analyses to be drawn. A more complicated case where the flexible down-scale membrane interacts with a propagated water wave is a further target area to study. Moreover, an experimental investigation is required to validate the numerical results by way of comparison. The ultimate goal is to perform a similitude analysis upon which a correlation between the full-scale prototype and the down-scale model can be formed. The implementation of the similarity laws enables the behavior of the full scale prototype to be quantitatively assessed on the basis of the available data for the down-scale model. In addition, in order to validate the accuracy of the similitude analysis, numerical analyses have to be carried out.:Contents Zusammenfassung I ABSTRACT IV Nomenclature X 1 Introduction 1 1.1 Work overview 2 1.2 Literature review 3 1.2.1 The non-conforming methods 6 1.2.2 The conforming (partitioned) approaches 11 1.2.2.1 Interface data transfer 16 1.2.2.2 Accuracy, stability and efficiency 16 1.2.2.3 Modification of interface conditions: Robin transmission conditions 18 1.3 Concluding remarks 19 2 Methodology-numerical methods for fluid-structure interaction analysis (FSI) 20 2.1 Single FV framework 21 2.1.1 The prism layer mesher 24 2.1.2 Turbulence modeling 24 2.2 Preparation of the standalone Abaqus model 27 2.2.1 Damping by bulk viscosity 28 2.2.2 Coulomb friction damping 29 2.2.3 Rayleigh damping 29 2.2.4 Determination of the Rayleigh damping parameters based on the Chowdhury procedure 29 2.2.5 The frequency response function (FRF) measurement 30 2.2.6 The half-power bandwidth method 31 2.3 Explicit partitioned coupling 33 2.4 Implicit partitioned coupling 39 2.5 Overset mesh 40 2.6 Concluding remarks 42 3 Verification and validation of the structural model 44 3.1 Numerical model setup of the down-scale membrane 44 3.2 Comparing similarity between numerical and experimental results 46 3.2.1 Hypothesis test terminology 46 3.2.2 Curve fitting 47 3.2.3 Similarity measures between two curves 48 3.3 Results (down-scale membrane) 52 3.3.1 Similarity tests for the contact length 54 3.3.2 Similarity tests for the slope 58 3.3.3 Similarity tests for the displacement in Y direction 60 3.4 Concluding remarks 63 4 Numerical model setup of the original membrane for impact analysis 66 4.1 Structure domain 67 4.2 Fluid domain 72 4.2.1 Standard mesh and results 74 4.2.2 Overset mesh 80 4.3 Co-simulation model setup and results 88 4.4 Concluding remarks 96 5 Numerical wave generation 100 5.1 Theoretical estimation of the waves 107 5.2 Numerical wave tank setup 110 5.3 Results 114 5.4 Concluding remarks 119 6 Validity of the model with dynamic pressure 121 6.1 Wave tank 123 6.2 Structure domain 127 6.3 Fluid domain 130 6.4 Co-simulation model setup 136 6.5 Experimental approach 137 6.6 Results 141 6.6.1 Similarity tests for the displacement of the membrane in X direction 156 6.6.2 Similarity tests for the displacement of the membrane in Y direction 160 6.6.3 Similarity tests for the displacement of the membrane in Z direction 164 6.7 Concluding remarks 168 7 Similarity 171 7.1 Motivation 171 7.2 Governing equations 174 7.3 Buckingham Pi theorem 175 7.4 Dimensionless numbers 175 Similitude requirement 177 7.5 Simulation setup 178 7.6 Results 179 7.7 Concluding remarks 191 8 Summary, conclusions and outlook 192 List of figures 199 List of tables 209 References 210

<p dir="ltr">Positive displacement machines are used in various industries spanning the power spectrum, from industrial robotics to heavy construction equipment to aviation. These machines should be highly efficient, compact, and reliable. It is very advantageous for designers to use virtual simulations to design and improve the performance of these units as they significantly reduce cost and downtime. The recent trends of electrification and the goal to increase power density force these units to work at higher pressures and higher rotational speeds while maintaining their efficiencies and reliability. This push means that the simulation models need to advance to account for various aspects during the operation of these machines. </p><p dir="ltr">These machines typically have several bodies in relative motion with each other. Quantifying these motions and solving for their effect on the fluid enclosed are vital as they influence the machine's performance. The push towards higher rotational speeds introduces unwanted cavitation and aeration in these units. To model these effects, keeping the design evaluation time low is key for a designer. The lumped parameter approach offers the benefit of computational speed, but a major drawback that comes along with it is that it typically assumes fluid inertia to be negligible. These effects cannot be ignored, as quantifying and making design considerations to negate these effects can be beneficial. Therefore, this thesis addresses these key challenges of cavitation dynamics, body dynamics, and accounting for fluid inertia effects using a lumped parameter formulation.</p><p dir="ltr">To account for dynamics features related to cavitation, this thesis proposes a novel approach combining the two types of cavitation, i.e., gaseous and vaporous, by considering that both vapor and undissolved gas co-occupy a spherical bubble. The size of the spherical bubble is solved using the Rayleigh-Plesset equation, and the transfer of gas through the bubble interface is solved using Henry's Law and diffusion of the dissolved gas in the liquid. These equations are coupled with a novel pressure derivative equation. To account for body dynamics, this thesis introduces a novel approach for solving the positions of the bodies of a hydraulic machine while introducing new methods to solve contact dynamics and the application of Elasto Hydrodynamic Lubrication (EHL) friction at those contact locations. This thesis also proposes strategies to account for fluid inertia effects in a lumped parameter-based approach, taking as a reference an External Gear Machine. This thesis proposes a method to study the effects of fluid inertia on the pressurization and depressurization of the tooth space volumes of these units. The approach is based on considering the fluid inertia in the pressurization grooves and inside the control volumes with a peculiar sub-division. Further, frequency-dependent friction is also modeled to provide realistic damping of the fluid inside these channels.</p><p dir="ltr">To show the validity of the proposed dynamic cavitation model, the instantaneous pressure of a closed fluid volume undergoing expansion/compression is compared with multiple experimental sources, showing an improvement in accuracy compared to existing models. This modeling is then further applied to a gerotor machine and validated with experiments. Integrating this modeling technique with current displacement chamber simulation can further improve the understanding of cavitation in hydraulic systems. Formulations for body dynamics are tested on a prototype Gerotor and Vane unit. For both gerotor and vane units, comparisons of simulation results to experimental results for various dynamic quantities, such as pressure ripple, volumetric, and hydromechanical efficiency for multiple operating conditions, have been done. Extensive validation is performed for the case of gerotors where shaft torque ripple and the motion of the outer gear is experimentally validated. The thesis also comments on the distribution of the different torque loss contributions. The model for fluid inertia effects has been validated by comparing the lumped parameter model with a full three-dimensional Navier Stokes solver. The quantities compared, such as tooth space volume pressures and outlet volumetric flow rate, show a good match between the two approaches for varying operating speeds. A comparison with the experiments supports the modeling approach as well. The thesis also discusses which operating conditions and geometries play a significant role that governs the necessity to model such fluid inertia effects in the first place.</p>