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This project is centred on an ongoing trailer component failure problem at the STEELBRO New Zealand Ltd due to cracks. In this research the problem has been systematically approached using ANSYS finite element analysis software. The approach involves investigation of the problem and structural analysis of the trailer subjected to two types of service conditions. The service conditions are simulated in ANSYS which involved CAD and finite element modelling of the trailer, and then the finite element model is validated experimentally by strain gauges and geometrically by ANSYS element shape checking capability. The finite element model subjected to static structural analysis confirmed the crack locations and indicated the cause of the failure. Further fatigue analysis on one of the loading condition revealed it’s potential to cause failure at the crack locations. Finally, this research concludes with a proposal of revised component design to overcome the failure at the crack locations and recommendations for further analysis on the trailer.

As bridges continue to age and budgets reduce, transportation officials often need quantitative data to distinguish between bridges that can be kept safely in service and those that need to be replaced or retrofitted. One of the critical types of structural deterioration for steel bridges is fatigue-induced fracture, and evaluating the daily fatigue damage through field measurements is one means of providing quantitative data to transportation officials. When analyzing data obtained through field measurements, methods are needed to properly evaluate fatigue damage. Five techniques for evaluating strain data were formalized in this dissertation. Simplified rainflow counting, which converts a stress history into a histogram of stress cycles, is an algorithm standardized by ASTM and the first step of a fatigue analysis. Two methods, effective stress range and index stress range, for determining the total amount of fatigue damage during a monitoring period are presented. The effective stress range is the traditional approach for determining the amount of damage, whereas the index stress range is a new method that was developed to facilitate comparisons of fatigue damage between sensors and/or bridges. Two additional techniques, contribution to damage and cumulative damage, for visualizing the data were conceived to allow an engineer to characterize the spectrum of stress ranges. Using those two techniques, an engineer can evaluate whether lower stress cycles (concern due to electromechanical noise from data acquisition system) and higher stress ranges (concern due to possible spike from data acquisition system) contribute significantly to the accumulation of damage in the bridge. Data from field measurements can be used to improve the estimate of the remaining fatigue life. Deterministic and probabilistic approaches for calculating the remaining fatigue life were considered, and three methods are presented in this dissertation. For deterministic approaches, the output of the equations is the year when the fatigue life has been exceeded for a specific probability of failure, whereas for probabilistic approaches, the probability of failure for a given year is calculated. Four different steel bridges were instrumented and analyzed according to the techniques outlined in this dissertation. / text

Vehicle anti-roll bars are suspension components used for limiting body roll angle. They have a direct effect on the handling characteristics of the vehicle. Design changes of anti-roll bars are quite common at various steps of vehicle production, and a design analysis must be performed for each change. Finite Element Analysis (FEA) can be effectively used in design analysis of anti-roll bars. However, due to high number of repeated design analyses, the analysis time and cost problems associated with the use of general FEA package programs may create considerable disadvantages in using these package programs for performing anti-roll bar design analysis. In this study, an automated design program is developed for performing design analysis of vehicle anti-roll bars. The program is composed of two parts, the user interface and the FEA macro. The FEA macro includes the codes for performing deformation, stress, fatigue, and modal analysis of anti-roll bars in ANSYS 7.0. The user interface, which is composed in Visual Basic 6.0, includes the forms for data input and result output procedures. By the developed software, the FEA of the anti-roll bars is simplified to simple data entry via user interface. The flow of the analysis is controlled by the program and the finite element analysis is performed by ANSYS at the background. The developed software can perform design analysis for a wide range of anti-roll bars: The bar centerline can have any 3D shape, the cross section can be solid or hollow circular, the end connections can be of pin or spherical joint type, the bushings can be mounted at any position on the bar with a user defined bushing length. The effects of anti-roll bar design parameters on final anti-roll bar properties are also evaluated by performing sample analyses with the automated design program developed in this study.

Indiana University-Purdue University Indianapolis (IUPUI) / Previous works suggest that 80% to 90% of failures observed in the rotary machines are accounted for fatigue failure. And it is observed that cyclic stresses are more critical than steady stresses when the failure occurred is due to fatigue. One of the most expensive industries involving rotary machines is the Oil and Gas industry. The large drilling tools are used for oil extracts on-shore and off-shore. There are several forces that act on a drilling tool while operating below the earth's surface. Those forces are namely pressure, bending moment and torque. The tool is designed from the baseline model of the former tool in Solidworks and Design Molder. Here load acting due to pressure and torque accounts for steady stress i.e., Mean Stress and loading acting due to bending moment account for fluctuating stress i.e., Alternating Stress. The loading and boundary conditions have been adapted from Halliburton’s previous works for the LWD drill tool to better estimate the size of the largest possible transducer. The fatigue analysis of static load cases is carried out in Ansys Mechanical Workbench 19.0 using static structural analysis. The simulation is run to obtain results for total deformation, equivalent stress, and user-defined results. The component is designed for infinite life to calculate the endurance limit. Shigley guidelines and FKM guidelines are compared as a part of a study to select the best possible approach in the current application. The width of the imaging pocket is varied from 1.25 inches to 2.0 inches to accommodate the largest possible transducer without compromising the structural integrity of the tool. The optimum design is chosen based on the stress life theory criteria namely Gerber theory and Goodman Theory.

The accuracy of computer-based ground vehicle durability and ride quality simulations depends on accurate representation of road surface topology as an excitation to vehicle dynamics simulation software, since most of the excitation input to a vehicle as it traverses terrain is provided by the surface topology. It is not computationally efficient to utilise physically measured terrain topology for these simulations since extremely large data sets would be required to represent terrain of all desired types. Moreover, performing repeated simulations on the same set of measured data would not provide a random character typical of real world usage. There exist several methods of synthesising terrain data through the use of stochastic or mathematical models in order to capture such physical properties of measured terrain as roughness, bank angle and grade. In first part of this work, the autoregressive model and the Markov chain model have been applied to generate synthetic two-dimensional terrain profiles. The synthesised terrain profiles generated are expected to capture the statistical properties of the measured data. A methodology is then proposed; to assess the performance of these models of terrain in capturing the statistical properties of the measured terrain. This is done through the application of several statistical property tests to the measured and synthesized terrain profiles. The second part of this work describes the procedure that has been followed to assess the performance of these models in capturing the vehicle component fatigue-inducing characteristics of the measured terrain, by predicting suspension component fatigue life based on the loading conditions obtained from the measured terrain and the corresponding synthesized terrain. The terrain model assessment methodology presented in this work can be applied to any model of terrain, serving to identify which terrain models are suited to which type of terrain. / Master of Science

Previous works suggest that 80% to 90% of failures observed in the rotary machines are accounted to fatigue failure. And it is observed that cyclic stresses are more critical than steady stresses when the failure occurred is due to fatigue. One of the most expensive industries involving rotary machines is the Oil and Gas industry. The large drilling tools are used for oil extracts on-shore and off-shore. There are several forces that act on a drilling tool while operating below the earth surface. Those forces are namely pressure, bending moment and torque. The tool is designed from the baseline model of the former tool in Solidworks and Design Molder. Here load acting due to pressure and torque accounts for steady stress i.e., Mean Stress and loading acting due to bending moment account for fluctuating stress i.e., Alternating Stress. The loading and boundary conditions have been adapted from Halliburton’s previous works for LWD drill tool to better estimate the size of the largest possible transducer. The fatigue analysis of static load cases is carried out in Ansys Mechanical Workbench 19.0 using static structural analysis. The simulation is run to obtain results for total deformation, equivalent stress, and user-defined results. The component is designed for infinite life to calculate the endurance limit. Shigley guideline and FKM guideline are compared as a part of a study to select the best possible approach in the current application. The width of the imaging pocket is varied from 1.25 inches to 2.0 inches to accommodate the largest possible transducer with compromising the structural integrity of the tool. The optimum design is chosen based on the stress life theory criteria namely Gerber theory and Goodman Theory.<br>

Confront with the serious aging problem in aircraft structure field, the profession was tasked to unveil the mysterious in the mechanism of aging. In decades, many endeavours were put into different subjects such as, fatigue and crack calculation, corrosion analysis, reliability evaluation, life prediction, structure monitor and protection, structure repair, etc. In an effort of developing a reasonable model for life prediction and reliability evaluation, a wide range of topics in the field of aging structure reliability are reviewed. Many existing methods and tools are carefully studied to distinguish the advantages, disadvantages and the special application. With consideration of corrosion fatigue life, and based on the data obtained through investigating service status of the aging aircraft, a fuzzy reliability approach is proposed and presented. Initially, the thesis presents the literature review in the field, introducing the well-established theories and analysis tools of reliability and points out how such these methods can be used to assess the life and reliability of aging structure. Meanwhile, some characteristic parameters and distributions, as well as some crucial calculation formulations, procedures for aging aircraft reliability/risk analysis are given. Secondly, mathematical models are established to evaluate the initial crack size and to assess both randomness and fuzziness of the variables, which also successfully work out the probability of survival of existing structures over a time period and predict the operation time under specific reliability requirement. As a practical approach to the reliability of aging aircraft structure, example is presented and evaluated. While conduct the calculation, a few programs based on FORTRAN code are developed to solve the none-linear equation, to work out the multi dimension integration and to simulate the survival probability. The crack life prediction software AFGROW is selected for comparison of the calculation results, which also shows the appropriate accuracy of the established model. As conclusion, the effects of some variables including fuzzy factors on reliability and life of aging aircraft structure are finally discussed. It is apparent that the confines of the model are existing as fact because of the huge assumption of the parameters input and model uncertainties. Suggestions on further prospective research are proposed respectively.

The heat flux produced from the friction between a disc and pad system leads to a high temperature which causes thermal stresses in the disc and after a number of repeated braking cycles, cracks might be initiated. The finite element analysis (FEA) is performed to determine the temperatures profile in the disc and to analyze the stresses for the repeated braking, which could be used to calculate the fatigue life of a disc.Sequentially coupled approach is used for thermo-mechanical problem and the problem is divided into two parts, heat analysis and thermal stress analysis. The heat analysis is obtained by including frictional heat and adopting an Eulerian approach. The heat analysis is conducted by using Abaqus and the toolbox developed by Niclas Strömberg. The thermal stress analysis, which is the main focus of this thesis, is followed using Abaqus. The plasticity theory as background for stress analysis is discussed in detail. The rate independent elasto-plastic plasticity is used in the stress analysis. Temperature independent material properties are considered throughout the thesis work.Isotropic, kinematic and combined hardening models are analyzed for simple 2D academic models for different types of cyclic loads. A benchmark disc and pad model, which is less complicated than the real disc-pad model, is also studied. The linear kinematic hardening model with rate independent elastic-plastic plasticity is used for benchmark and real disc-pad model. The results of the benchmark model and the real model are observed to be similar in terms of plasticity theory.

Due to its inherent complexity such as limited work volume and degree of freedom, minimally invasive surgery (MIS) is ergonomically challenging to surgeons than traditional open surgery. Specifically, MIS can expose performing surgeons to excessive ergonomic risks including muscle fatigue that may lead to critical errors in surgical procedures. Therefore, detecting the vulnerable muscles and time-to-fatigue during MIS is of great importance in order to prevent these errors. In this research, different surgical skill and ergonomic assessment methods are reviewed and their advantages and disadvantages are studied. According to the literature review, which is included in chapter 1, some of these methods are subjective and those that are objective provide inconsistent results. Muscle fatigue analysis has shown promising results for skill and ergonomic assessments. However, due to the data analysis issues, this analysis has only been successful in intense working conditions. The goal of this research is to apply an appropriate data analysis method to minimally invasive surgical setting which is considered as a low-force muscle activity. Therefore, surface electromyography is used to record muscle activations of subjects while they performed various real laparoscopic operations and dry lab surgical tasks. The muscle activation data is then reconstructed using Recurrence Quantification Analysis (RQA), which has been proven to be a reliable analysis, to detect possible signs of muscle fatigue on different muscle groups. The results of this data analysis method is validated using subjective fatigue assessment method. In order to study the effect of muscle fatigue on subject’s performance, standard Fundamental of Laparoscopic Surgery (FLS) tasks performance analysis is used.