In many parts of the world, civilians and peacekeepers are exposed to potentially serious injury from blasts and explosions. Providing insight into the trauma thresholds for blast injury is necessary for the development of blast protection equipment and identification and subsequent treatment of blast injury. [Phillips, 1988] Blast injury can be categorized as primary, secondary, tertiary, quaternary and quinernary, corresponding to different aspects of the blast loading and injury mechanisms. Primary blast injury occurring in the lungs is of importance, since lung injury results in one of the highest rate of blast mortality. Much of the existing blast injury data was obtained from animal testing with sheep and subsequently extrapolated to humans using scaling techniques. More recently, mathematical, experimental and numerical models have been developed and employed to investigate blast injury. In this study, a detailed finite element model of a sheep thorax and human thorax (developed at the University of Waterloo) was used to predict primary blast lung injury based on a range of blast loading conditions. The models were developed based on available anatomical data and material properties to model the organs and tissues, and were evaluated using the LS-Dyna explicit finite element code. The models were previously validated for the prediction of lung PBI using Friedlander-type blast waves. All results were compared to existing literature to further verify and validate the numerical models as wells as to provide insight on the effect of loading conditions on blast injury. The blast loading input for these simulations used idealized blast waves, based on a blast physics approach. Blast loads were verified using the Chinook CFD software. The effects of idealized blast waves on predicted lung injury were investigated to determine the importance of peak pressure, blast wave duration and impulse. The duration and peak pressures for the waves were selected based on the Bowen and UVa curves, and included a right angle triangular shape and a square wave to allow for the different parameters to be considered. These results were compared to the Bowen and revised Bowen injury models. The results show that the peak overpressure is dominant in predicting injury for blast loads with long durations (>8 ms). The impulse was dominant in predicting injury for blast loads with short durations (<1 ms). For blasts loads with intermediate durations (1 ms < 8 ms) both the shape of the blast load wave and peak overpressure play a role in primary blast lung injury. The effect of orientation of the body position on primary blast lung injury was investigated. Simulations were performed using the sheep and human numerical models along with a model of a commonly used experimental device, the Blast Test Device (BTD) cylinder. These models were oriented in different positions by rotating the body relative to the blast flow. Injury results for the BTD were calculated using the Injury 8.1 injury prediction software. The BTD simulations served several purposes; it was used as a reference for the human and sheep simulations and its effectiveness as a tool to predict body orientation was evaluated. In general, all of the models predicted appropriate and similar levels of injury for the body in its default orientation, and these predictions were comparable to the accepted injury levels for this insult. For other orientations the BTD was not able to predict the appropriate blast injury. This highlighted the importance of proper placement and orientation of the BTD when used in simulations or physical experiments. The overall injury (based on the results from the right and left lung) predicted by the sheep and human thorax was similar for all orientations. However, very different results were obtained when the predicted injury for the right and left lungs was compared. The differences between the sheep and the human were examined and the differences in injury between the right and left lung is a result of the differences in anatomy between the two species. This study has evaluated the importance of blast wave parameters in predicting primary blast injury, an important consideration for the improvement of blast protection, and the effect of body orientation on primary blast injury, an important consideration for experimental testing and a starting point for the evaluation of complex blast loading. Future work will focus on the evaluation of injury in complex blast environments.

In many parts of the world, civilians and peacekeepers are exposed to potentially serious injury from blasts and explosions. Providing insight into the trauma thresholds for blast injury is necessary for the development of blast protection equipment and identification and subsequent treatment of blast injury. [Phillips, 1988] Blast injury can be categorized as primary, secondary, tertiary, quaternary and quinernary, corresponding to different aspects of the blast loading and injury mechanisms. Primary blast injury occurring in the lungs is of importance, since lung injury results in one of the highest rate of blast mortality. Much of the existing blast injury data was obtained from animal testing with sheep and subsequently extrapolated to humans using scaling techniques. More recently, mathematical, experimental and numerical models have been developed and employed to investigate blast injury. In this study, a detailed finite element model of a sheep thorax and human thorax (developed at the University of Waterloo) was used to predict primary blast lung injury based on a range of blast loading conditions. The models were developed based on available anatomical data and material properties to model the organs and tissues, and were evaluated using the LS-Dyna explicit finite element code. The models were previously validated for the prediction of lung PBI using Friedlander-type blast waves. All results were compared to existing literature to further verify and validate the numerical models as wells as to provide insight on the effect of loading conditions on blast injury. The blast loading input for these simulations used idealized blast waves, based on a blast physics approach. Blast loads were verified using the Chinook CFD software. The effects of idealized blast waves on predicted lung injury were investigated to determine the importance of peak pressure, blast wave duration and impulse. The duration and peak pressures for the waves were selected based on the Bowen and UVa curves, and included a right angle triangular shape and a square wave to allow for the different parameters to be considered. These results were compared to the Bowen and revised Bowen injury models. The results show that the peak overpressure is dominant in predicting injury for blast loads with long durations (>8 ms). The impulse was dominant in predicting injury for blast loads with short durations (<1 ms). For blasts loads with intermediate durations (1 ms < 8 ms) both the shape of the blast load wave and peak overpressure play a role in primary blast lung injury. The effect of orientation of the body position on primary blast lung injury was investigated. Simulations were performed using the sheep and human numerical models along with a model of a commonly used experimental device, the Blast Test Device (BTD) cylinder. These models were oriented in different positions by rotating the body relative to the blast flow. Injury results for the BTD were calculated using the Injury 8.1 injury prediction software. The BTD simulations served several purposes; it was used as a reference for the human and sheep simulations and its effectiveness as a tool to predict body orientation was evaluated. In general, all of the models predicted appropriate and similar levels of injury for the body in its default orientation, and these predictions were comparable to the accepted injury levels for this insult. For other orientations the BTD was not able to predict the appropriate blast injury. This highlighted the importance of proper placement and orientation of the BTD when used in simulations or physical experiments. The overall injury (based on the results from the right and left lung) predicted by the sheep and human thorax was similar for all orientations. However, very different results were obtained when the predicted injury for the right and left lungs was compared. The differences between the sheep and the human were examined and the differences in injury between the right and left lung is a result of the differences in anatomy between the two species. This study has evaluated the importance of blast wave parameters in predicting primary blast injury, an important consideration for the improvement of blast protection, and the effect of body orientation on primary blast injury, an important consideration for experimental testing and a starting point for the evaluation of complex blast loading. Future work will focus on the evaluation of injury in complex blast environments.

Over the past 50 years, electronics manufacturing industry has undergone revolutionary changes, which have provided consumers with a plethora of electronic products. The increase in functionality of electronic products and decrease in cost due to continuous miniaturization and lower manufacturing costs have evolved over time. As electronics manufacturing technology becomes more advanced, reliability of electronic products and devices have become more of a concern. Thermomechanical reliability in electronics is studied in this research. Thermomechanical failures are failures due to temperature loading conditions electronic products and devices experience during manufacturing and service. The thermomechanical issue studied in this research is the effect of convective solder reflow on the warpage of packaged electronic devices, bare boards and chip packages. A convective reflow-projection moir warpage measurement system is designed and implemented in this research. The system is the first available system capable of measuring warpage of printed wiring boards (PWBs) with and without electronic components during simulated convective reflow process. A finite element prediction tool is also developed to predict the warpage of PWBs populated with plastic ball grid array (PBGA) packages. The developed warpage measurement system as well as the developed finite element model is used to study various PWB assembly (PWBA) configurations during simulated convective reflow processes.

This thesis develops a finite element based dynamic modeling method for design and analysis of compliant mechanisms which transfer input force, displacement and energy through elastic deformations. Most published analyses have largely based on quasi-static and lump-parameter models neglecting the effects of damping, torsion, complex geometry, and nonlinearity of deformable contacts. For applications such as handling of objects by the robotic hands with multiple high-damped compliant fingers, there is a need for a dynamic model capable of analyzing the flexible multibody system. This research begins with the formulation of the explicit dynamic finite element method (FEM) which takes into account the effects of damping, complex geometry and contact nonlinearity. The numerical stability is considered by evaluating the critical time step in terms of material properties and mesh quality. A general framework incorporating explicit dynamic FEM, topology optimization, modal analysis, and damping identification has been developed. Unlike previous studies commonly focusing on geometry optimization, this research considers both geometric and operating parameters for evaluation where the dynamic performance and trajectory of the multibody motion are particularly interested. The dynamic response and contact behavior of the rotating fingers acting on the fixed and moving objects are validated by comparing against published experimental results. The effectiveness of the dynamic modeling method, which relaxes the quasi-static assumption, has been demonstrated in the analyses of developing an automated transfer system involved grasping and handling objects by the compliant robotic hands. This FEM based dynamic model offers a more realistic simulation and a better understanding of the multibody motion for improving future design. It is expected that the method presented here can be applied to a spectrum of engineering applications where flexible multibody dynamics plays a significant role.

<p>Intensive competition on the global market puts great pressure on manufacturing companies to develop and produce products that meet requirements from customers and investors. One key factor in meeting these requirements is the efficiency of the product development and the production preparation process. Design automation is a powerful tool to increase efficiency in these two processes.</p><p>The benefits of automating the production preparation process are shortened led-time, improved product performance, and ultimately decreased cost. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in few or in a single step. During the automation process, knowledge about the production preparation process is collected and stored in central systems, thus allowing full control over the design of production equipments.</p><p>Three main topics are addressed in this thesis: the flexibility of design automation systems, knowledge bases containing conflicting rules, and the automation of the finite element analysis process. These three topics are discussed in connection with the production preparation process of rotary draw bending.</p><p>One conclusion drawn from the research is that it is possible to apply the concept of design automation to the production preparation process at different levels of automation depending on characteristics of the implemented knowledge. In order to make design automation systems as flexible as possible, the concept of object orientation should be adapted when building the knowledge base and when building the products geometrical representations. It is possible to automate the process of setting up, running, and interpreting finite element analyses to a great extent and making the automated finite element analysis process a part of the global design automation system.</p>

<p>Composite structures can lower the weight of an airliner significantly. The increased production cost, however, requires the application of cost-effective design strategies. Hence, a comparative value is required which is used for the evaluation of a design solution in terms of cost and weight. The direct operating cost (DOC) can be used as this comparative value; it captures all costs that arise when the aircraft is flown. In this work, a cost/weight optimization framework for composite structures is proposed. It takes into account manufacturing cost, non-destructive testing cost and the lifetime fuel consumption based on the weight of the aircraft, thus using a simplified version of the DOC as the objective function.</p><p>First, the different phases in the design of an aircraft are explained. It is then focused on the advantages and drawbacks of composite structures, the design constraints and allowables, and non-destructive inspection. Further, the topics of multiobjective optimization and the combined optimization of cost and weight are addressed. Manufacturing cost can be estimated by means of different techniques; here, feature-based cost estimations and parametric cost estimations proved to be most suitable for the proposed framework. Finally, a short summary of the appended papers is given.</p><p>The first paper contains a parametric study in which a skin/stringer panel is optimized for a series of cost/weight ratios (weight penalties) and material configurations. The weight penalty, defined as the specific lifetime fuel burn, is dependent on the fuel consumption of the aircraft, the fuel price and the viewpoint of the optimizer. It is concluded that the ideal choice of the design solution is neither low-cost nor low-weight but rather a combination thereof.</p><p>The second paper proposes the inclusion of non-destructive testing cost in the design process of the component, and the adjustment of the design strength of each laminate according to the inspection parameters. Hence, the scan pitch of the ultrasonic testing is regarded as a variable, representing an index for the (guaranteed) laminate quality. It is shown that the direct operating cost can be lowered when the quality level of the laminate is assigned and adjusted in an early design stage.</p>

To model shrink-fitting in metal components, an analytical model for two long compound cylinders with temperature dependent material properties and interference between them is developed for calculating transient temperatures and stresses. A finite element model is developed for the same geometry which incorporated the temperature dependent material properties. A convergence study is performed on the finite element and analytical model. The finite element model is validated by comparing the approximations of finite element model with the analytical solution. In an assembly procedure of fulcrums for bascule bridges, called AP1, the trunnion is shrink-fitted into a hub, followed by shrink fitting the trunnion-hub assembly into the girder of the bridge. In another assembly procedure called AP2, the hub is shrink-fitted into the girder, followed by shrink-fitting the trunnion in the hub-girder assembly. A formal design of experiments (DOE) study is conducted on both AP1 and AP2 using the finite element model to find the influence of geometrical parameters such as radial thickness of the hub, radial interference, and various shrink-fitting methods on the design parameter of overall minimum critical crack length (OMCCL) - a measure of likelihood of failure by cracking. Using the results of DOE study conducted on both the assembly procedures, AP1 and AP2 are quantitatively compared for the likelihood of fracture during assembly. For single-staged shrink-fitting methods, for high and low hub radial thickness to hub inner diameter ratio, assembly procedure AP1 and AP2 are recommended, respectively. For fulcra with low hub radial thickness to hub inner diameter ratio and where staged shrink-fitting methods are used, for AP2, cooling the trunnion in dry-ice/alcohol and heating the girder, and for AP1, cooling the trunnion-hub assembly in dry-ice/alcohol followed by immersion in liquid nitrogen is recommended. For fulcra with high hub radial thickness to hub inner diameter ratio and where staged shrink-fitting methods are used, cooling the components in dry-ice/alcohol and heating the girder is recommended for both AP1 and AP2. Due to the limitations of AP2, assembly procedures by heating the girder with heating coils instead of dipping an already stressed trunnion-hub assembly in liquid nitrogen are studied for decreasing the likelihood of failure by cracking and yielding. In an assembly procedure called AP3-A, only the girder is heated to shrink-fit the trunnion-hub assembly in the girder. This assembly procedure AP3-A is found to be infeasible because the girder fails by yielding if heating is expected to be completed in a reasonable amount of time. An alternative assembly procedure called AP3-B is suggested for shrink-fitting where the heating of the girder is combined with cooling the trunnion-hub assembly in dry-ice/alcohol mixture. This assembly procedure AP3-B is found to be feasible. A complete DOE study is conducted on AP3-B to find the influence of parameters like hub radial thickness and radial interference at trunnion-hub interface on the design parameter of overall minimum critical crack length. The design parameter, OMCCL values during the assembly procedure AP3-B are quantitatively compared with the widely used assembly procedures (AP1 single-stage shrink-fitting and AP1 multi-staged shrink fitting). The results of this work suggest that increasing the hub radial thickness decreases the likelihood of fracture significantly. For hubs with large radial thickness, heating the girder combined with cooling the trunnion-hub in dry-ice/alcohol mixture (AP3-B) is recommended but for hubs with low radial thickness, multistage cooling of the trunnion-hub assembly in dry-ice/alcohol mixture followed by dipping in liquid nitrogen (AP1- multistage cooling) is recommended.

Recycling of plastics always plays an important role in keeping our environment better and safe. With the rise in usage of plastics and industrialization, the need for recycling the plastics has become a big business and is getting bigger. This thesis work was done for a company called Rapid Granulator AB, which works with the recycling of plastics as a big trade in Sweden. Like all the industries across the globe are trying to be economical in every way, Rapid Granulator AB wanted to develop an economical design of their high quality granulating knife. For achieving the economical design, they wanted to study the behaviour of the rotating knife during the process of producing plastic granules. The granulator cutting process was simulated and numerical analysis was done on the rotating knife of a plastic granulator machine by using the finite element code ABAQUS with 3D stress elements to find out the critical stresses and forces acting on the rotating knife. The bolt preload was applied by Abaqus/Standard, and the results of implicit analysis were imported to Abaqus/Explicit for the impact analysis where the flow of stresses on the rotating knife during the impact with materials were simulated and studied. The study was done on knife models of different thickness to see if the thickness of the current knife model can be reduced. Analysis were done also on a knife model assembly with a double sided cutting edge knife to see if the knife model can be used to its full extent. The simulation models and analysis results were given to the company to develop a more economical knife model.

The material development cycle is becoming too slow if compared with other technologies sectors like IT and electronics. The materials scientists’ community needs to bring materials science back to the core of human development. ICME (Integrated Computational Materials Engineer) is a new discipline that uses advanced computational tools to simulate material microstructures, processes and their links with the final properties. There is the need for a new way to design tailor-made materials with a faster and cheaper development cycle while creating products that meet “real-world” functionalities rather than vague set of specifications. Using the ICME approach, cutting edge computational thermodynamics models were employed in order to assist the microstructure characterization and refinement during the TIG welding of a functionally graded composite material with outstanding wear and corrosion resistance. The DICTRA diffusion model accurately predicted the carbon diffusion during sintering, Thermo-Calc and TC-PRISMA models described the thermodynamic and kinetics of harmful carbide precipitation, while COMSOL Multhiphysic furnished the temperature distribution profile at every timestep during TIG welding of the material. Bainite transformation and the influence of chromium and molybdenum was studied and modelled with MAP_STEEL software. The simulations were then compared with experimental observations and a very good agreement between computational works and experiments was found for both thermodynamic and kinetics predictions. The use of this new system proved to be a robust assistance to the classic development method and the material microstructures and processes were carefully adjusted in order to increase corrosion resistance and weldability. This new approach to material development can radically change the way we think and we make materials. The results suggest that the use of computational tools is a reality that can dramatically increase the efficiency of the material development.

In dieser Arbeit wurde ein Arbeitsablauf entwickelt, um ein möglichst realistisches, biomechanisches Modell eines menschlichen Schädelknochens anhand eines Patienten-CT Datensatzes zu erstellen. Mit diesem Modell konnten Experimente aus der Literatur realistisch nachgestellt und anschließend der Mechanismus einer Orbitawandfraktur genauer untersucht werden. Es konnte gezeigt werden, dass das entwickelte Schädelmodell als Alternative für experimentelle biomechanische Untersuchungen verwendet werden kann. Somit sind eine Vielzahl parametrischer biomechanischer Studien möglich, ohne dabei auf Humanpräparate angewiesen zu sein.