Finite element(FE) method has been used to model cutting process since 1970s. However, it requires special techniques to cope with the difficulties in simulating extremely large strain when compare to static or small deformation problems. With the advancement of FE techniques, researchers can now have a deeper insight of the mechanism of material flow and chip formation of metal cutting process. Even the stagnation effect of the workpiece material in front of the cutting edge radius can be captured by using FE techniques such as Remeshing and Arbitrary Lagrangian Eulerian(ALE) formulation. However most of this models are limited to plane strain assumption which means they are 2-dimensional. Although 3D models are existing in the literatures, most of them employ Remeshing technique which is very computationally intensive and has many critics regarding its accuracy due to its frequent remeshing and mapping process. The rest of the 3D models employ Lagrangian formulation. The 3D models by Lagrangian formulation have the same limitations and drawbacks as in 2D models, as it requires failure criteria and in most of the cases predefined partition surfaces are also required. ALE technique on the other hand resolves all the drawbacks of the other formulations, it not only inherits the advantages of the other techniques but also has its own unique advantages such as it can simulate a longer time span up to couple seconds more economically by fixing the number of elements used. Although it's commonly accepted that ALE formulation is superior to other formulations of techniques in modeling metal cutting process, its usage is only limited to 2D models. Limited 3D ALE metal cutting models is available in the literature. Thus the main objective of this research is to explore the possibility of building a 3D metal cutting model with ALE formulation. The reliability and limitations will also be studied. Furthermore, Couple Eulerian-Lagrangian(CEL) formulation is a recent developed formulation that has a lot of potential in modeling metal cutting process in 3D. It will be compared with ALE models to study its potential and limitations in modeling metal cutting process. A new frictional model will also be proposed, which suggests that the frictional phenomenon in metal cutting is a consolidated effect of both friction between material interface and shear yield of the workpiece material. This idea provide a brand new perspective of viewing the friction phenomenon of metal cutting compared to those existed models. / Thesis / Master of Science (MSc)

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This work has been done in collaboration with Northpower Stålhallar AB. The work is concentrating on column buckling, wind load and deflection of steel columns made of VKR profiles. VKR profiles are steel profiles that are hot-rolled structural pipes having a rectangular section. The analysis is made according to Eurokod 3 and with the finite element program Abaqus. A comparison has been made between these to see whether they differ in result or not regarding buckling curves and interaction formulas. In addition, the company wanted calculation templates in Excel. A proposal for a spreadsheet for different deflection limits are presented in Excel that the company can use, as well as a calculation template for wind loads where all municipalities in Sweden are included. The report contains theoretical background on how to design columns with respect to buckling, wind loading and deflection according to Eurokod 3.The work with Abaqus includes linear and non-linear analysis of column buckling. The analyses also include geometric imperfections, residual stresses, and plastic behavior of steel. The result showed a slight difference between Eurokod and Abaqus analyses but it was not a considerable deviation.

A three dimensional nonlinear finite element model has been developed to study the behaviour of composite beams with profiled sheeting oriented perpendicular to its axis. The analysis of the push test was carried out using ABAQUS/Explicit with slow load application to ensure a quasi-static solution. Both material and geometric nonlinearities were taken into account. Elastic¿plastic material models were used for all steel components and the Concrete Damaged Plasticity model was used for the concrete slab. The post-failure behaviour of the push test was accurately predicted, which is crucial for realistic determination of shear capacity, slip and failure mode. The results obtained from finite element analysis were verified against the experimental push tests conducted in this research and also from other studies. After validation, the model was used to carry out an extensive parametric study to investigate the effect of transverse spacing in push tests with double studs placed in favourable and staggered positions with various concrete strengths. The results were also compared with the capacity of a single shear stud. It was found that shear connector resistance of pairs of shear connectors placed in favourable position was 94% of the strength of a single shear stud on average, when the transverse spacing between studs was 200 mm or more. For the same spacing, the resistance of staggered pairs of studs was only 86% of the strength of a single stud. The strength of double shear studs in favourable position was higher than that of the staggered pairs of shear connectors.

Master of Science / Department of Civil Engineering / Hani G. Melhem / The objective of this research is to use structure ambient random vibration response to detect damage level and location. The use of ambient vibration is advantageous because excitation is caused by service conditions such as normal vehicle traffic on a highway bridge, train passage on a railroad bridge, or wind loads on a tall building. This eliminates the need to apply a special impact or dynamic load, or interrupt traffic on a bridge in regular service. This research developed an approach in which free vibration of a structure is extracted from the response of this structure to a random excitation in the time domain (acceleration versus time) by averaging out the random component of the response. The result is the free vibration that includes all modes based on the sampling rate on time. Then this free vibration is transferred to the frequency domain using a Fast Fourier Transform (FFT). Variations in frequency response are a function of structural stiffness and member end-conditions. Such variations are used as a measure to identify the change in the structural dynamic properties, and ultimately detect damage. A physical model consisting of a 20 × 20 × 1670 -mm long steel square tube was used to validate this approach. The beam was tested under difference supports conditions varying from a single- to three-span continuous configuration. Random excitation was applied to the beam, and the dynamic response was measured by an accelerometer placed at various locations on the span. A numerical model was constructed in ABAQUS and the dynamic response was obtained from the finite element model subjected to similar excitation as in the physical model. Numerical results were correlated against results from the physical model, and comparison was made between the different span/support configurations. A subsequent step would be to induce damage that simulates loss of stiffness or cracking condition of the beam cross section, and that would be reflected as a change in the frequency and other dynamic properties of the structure. The approach achieved good results for a structure with a limited number of degrees of freedom. Further research is needed for structures with a larger number of degrees of freedom and structures with damage in symmetrical locations relative to the accelerometer position.

This work presents a study and implementation of the simulation of residual stresses in castings. The objects of study are a cast iron truck Hub part (provided by the company Volvo 3P) and an optimized version of the Hub resulting from the application of a topology optimization process. The models are solved through an uncoupled thermo-mechanical solidification analysis, performed both in the FE commercial software Abaqus and the FD commercial software Magmasoft and the results are compared. First, a thermal analysis is carried out where the casting is cooled down from a super-heated temperature to room temperature. The thermal history obtained, is then used as an external force to calculate the residual stresses by means of a quasi-static mechanical analysis, using a J2-plasticity model. The simulation procedures are explained through a simplified model of the Hub and then applied to the geometries of interest. A results comparison between the original Hub and its optimized version is also presented. The theoretical base is given in this work as well as detailed implementation procedures. The results shows that the part subjected to the topology optimization process develop less residual stresses than its original version.