These days, automotive industries are facing intensive competition. New products should be delivered into market as soon as possible. On the other hand, customers also require new products having good reliability. Laboratory life testing is the traditional way to examine the reliability of products. Sample products should be tested till failures, which usually involve tremendous cost and time. Obviously, the reliability testing process extends the duration of 'design-to-market'. Cutting down the testing process can reduce the producing cycle properly. Currently, the accelerated life test (ALT) has been widely used in many companies as an alternative method. Although ALT reduces the cost of reliability testing through applying more severe environmental conditions than the normal ones on products, it is no longer sufficient as it does not describe the process of products' failure explicitly and it is still highly dependent on physical testing. Consequently, prediction models need to be developed for better understanding of the products' reliability.

Thesis (M.S.)--University of Toledo, 2008. / "In partial fulfillment of the requirements for the degree of Master of Science in Biomedical Sciences." Title from title page of PDF document. Bibliography: p. 96-109.

Orientador: Fernando Eidi Takahashi / Banca: Alexandre Luiz Souto Borges / Banca: Cristiane Aparecida de Assis Claro / Resumo: O objetivo deste trabalho foi avaliar a localização e distribuição das tensões geradas ao redor de implantes com pilares protéticos de diferentes conexões cone Morse através da análise fotoelástica (AFE) e do método dos elementos finitos (MEF). Para o MEF, implante e pilares protéticos de diferentes conexões cone Morse (hexagonado e sólido) foram digitalizados pela técnica da microtomografia computadorizada e, com auxílio de softwares computacionais foi realizada a modelagem da malha tridimensional e o carregamento dos objetos. Foi realizada a caracterização das propriedades mecânicas da resina fotoelástica. Foram simulados blocos com propriedades mecânicas de osso cortical e trabecular e de resina fotoelástica. A AFE foi realizada a partir de blocos de resina fotoelástica onde foram incluídos os implantes aparafusados aos diferentes pilares protéticos. Estes blocos foram confeccionados a partir de um bloco prototipado do modelo utilizado no MEF. Os corpos-deprova foram imersos em um recipiente com óleo mineral e o conjunto foi observado no polariscópio circular com dispositivo de aplicação de cargas acoplado e recebendo a mesma carga, em sentido e posição iguais. Foi feita análise descritiva para as imagens obtidas em ambas as metodologias onde observou-se que: as imagens obtidas no MEF apresentaram distribuição de tensões bastante similar entre os dois modelos com diferentes pilares protéticos. Foram observadas diferenças entre a distribuição das tensões em blocos ósseo e de resina; As imagens obtidas na AFE se assemelharam às obtidas em MEF com bloco de resina. As imagens da AFE também foram analisadas quantitativamente, por comparação a valores atribuídos às franjas. A concordância interobservadores foi conferida pelo teste de Dahlberg. Concluiu-se que o Pilar Sólido transfere cargas mais homogeneamente para o osso adjacente ao implante... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The goal of this study was to evaluate the location and distribution of stresses generated around implants with different Morse taper connections abutments by photoelastic (PA) and finite element analysis (FEA). For FEA, implant and abutments with different Morse taper connections (hexagonal and solid) were scanned by computerized microtomography technique. The tridimensional mesh was modeled and the objects were loaded with the help of computer software. Photoelastic resin was characterized by mechanical properties. Trabecular and cortical bone and photoelastic resin blocks were simulated with their respective mechanical properties. The PA was performed with photoelastic resin blocks where implants were included and the different abutments were bolted. These blocks were made from a prototyped block of model used in FEA. Specimens were immersed in a mineral oil container and it was observed in the circular polariscope with the application device attached, where loads were received on same charge, on equal direction and position. Images obtained in both methodologies were descriptively analyzed where it was that: FEA images showed very similar stress distribution between two models with different abutments. Differences were observed between stress distribution in bone and resin blocks; PA images resembled those obtained on resin block FEA. PA images were also quantitatively analyzed by comparing the values assigned to fringes. Inter-observer agreement was given by Dahlberg test. It was concluded that solid abutment distributes loads more evenly to bone adjacent to implant compared with hexagonal abutment, for both analysis methods employed. Among the methodologies employed, it was observed that the PA has generated very similar results to those obtained in FEA with resin block, but different to those obtained in FEA when the clinical condition of the bone block was simulated / Mestre

This thesis presents and evaluates a number of finite element footstrike models developed to allow the performance of prospective athletic footwear designs to be evaluated in a virtual environment. Successful implementation of such models would reduce the industry's traditional reliance on physical prototyping and therefore reduce the time and associated costs required to develop a product. All boundary conditions defined in each of the footstrike models reported were directly determined from biomechanical motion capture trials to ensure that the loading applied was representative of shod human running. Similarly, the results obtained with each model were compared to digitised high speed video footage of experimental trials and validated against biomechanical measures such as foot segment kinematics, ground reaction force and centre of pressure location. A simple model loaded with triaxial force profiles determined from the analysis of plantar pressure data was found to be capable of applying highly representative load magnitudes but the distribution of applied loading was found to be less accurate. Greater success at emulating the deformation that occurs in the footwear during an entire running footstrike was achieved with models employing kinematic foot segment boundary conditions although this approach was found to be highly sensitive to the initial orientation of the foot and footwear components, thus limiting the predictive capacity of such a methodology. A subsequent model was therefore developed to utilise exclusively kinetic load conditions determined from an inverse dynamic analysis of an experimental trial and demonstrated the greatest predictive capacity of all reported models. This was because the kinematics of the foot were allowed to adapt to the footwear conditions defined in the analysis with this approach. Finally, the reported finite element footstrike models were integrated with automated product optimisation techniques. A topology optimisation approach was first utilised to generate lightweight midsole components optimised for subject-specific loading conditions whilst a similar shape optimisation methodology was subsequently used to refine the geometry of a novel footwear design in order to minimise the peak material strains predicted.

AN ABSTRACT OF THE THESIS OF Olanrewaju Ari Adeniyi for the Master of Science degree in Mechanical Engineering and Energy Processes presented June 2012, at Southern Illinois University Carbondale Title: FUSION OF ULTRASONIC C-SCAN DATA WITH FINITE ELEMENT ANALYSIS Major Professor: Dr. Tsuchin Philip Chu Ultrasonic testing is a highly valued method in the field of Non-destructive testing (NDT). It is an engineering tool that allows for non-invasive testing and evaluation. It is used widely in the aerospace industry to determine the integrity of complex materials without the use of destructive measures. This method of testing can be utilized to provide multitude of parameters such as material properties and thicknesses. It can also be used to test for discrepancies in test specimen such as voids, impurities, delamination and other defects that could degrade the integrity of a structure. The problem is that this method is limited in the area of evaluation of end results. Results are generated in the form of data images and are evaluated for quality or quantitative image assessment. Simulation models are created from an image, which causes low accuracy of analysis. The integration of Ultrasonic C-scan data with Finite Element Analysis (FEA) addresses these issues. It allows for models to be generated from Ultrasonic C-scan data, which provides the means to conduct accurate FEA simulations. The fusion of Ultrasonic C-scan data with computational methods, such as FEA, allows tested materials to be subjected to loading conditions that may be experienced in actual use. The results from FEA analysis can provide localized stress and strain fields generated from the loading conditions. The success of this analysis relies on the ability to generate high quality C-scan data to create accurate CAD data models. The generation of high quality scans will produce vital analysis information such as material properties, thickness, voids, surface inclusions and other critical deformities, all which will be used to generate a CAD analysis. With the ultrasonic data generated, finite element analysis can be utilized to further evaluate tested specimen. This technique has been applied to an isotropic aluminum block standard and an anisotropic Carbon Fiber Reinforced Polymer sample, both with known defects.

Efficient uncertainty propagation schemes for dynamical systems are investigated here within the framework of stochastic finite element analysis. Uncertainty in the mathematical models arises from the incomplete knowledge or inherent variability of the various parametric and geometric properties of the physical system. These input uncertainties necessitate the use of stochastic mathematical models to accurately capture their behavior. The resolution of such stochastic models is computationally quite expensive. This work is concerned with development of model order reduction techniques for obtaining the dynamical response statistics of stochastic finite element systems. Efficient numerical methods have been proposed to propagate the input uncertainty of dynamical systems to the response variables. Response statistics of randomly parametrized structural dynamic systems have been investigated with a reduced spectral function approach. The frequency domain response and the transient evolution of the response of randomly parametrized structural dynamic systems have been studied with this approach. An efficient discrete representation of the input random field in a finite dimensional stochastic space is proposed here which has been integrated into the generic framework of the stochastic finite element weak formulation. This framework has been utilized to study the problem of random perturbation of the boundary surface of physical domains. Truncated reduced order representation of the complex mathematical quantities which are associated with the stochastic isoparametric mapping of the random domain to a deterministic master domain within the stochastic Galerkin framework have been provided. Lastly, an a-priori model reduction scheme for the resolution of the response statistics of stochastic dynamical systems has also been studied here which is based on the concept of balanced truncation. The performance and numerical accuracy of the methods proposed in this work have been exemplified with numerical simulations of stochastic dynamical systems and the convergence behavior of various error indicators.

abstract: Laminated composite materials are used in aerospace, civil and mechanical structural systems due to their superior material properties compared to the constituent materials as well as in comparison to traditional materials such as metals. Laminate structures are composed of multiple orthotropic material layers bonded together to form a single performing part. As such, the layup design of the material largely influences the structural performance. Optimization techniques such as the Genetic Algorithm (GA), Differential Evolution (DE), the Method of Feasible Directions (MFD), and others can be used to determine the optimal laminate composite material layup. In this thesis, sizing, shape and topology design optimization of laminated composites is carried out. Sizing optimization, such as the layer thickness, topology optimization, such as the layer orientation and material and the number of layers present, and shape optimization of the overall composite part contribute to the design optimization process of laminates. An optimization host program written in C++ has been developed to implement the optimization methodology of both population based and numerical gradient based methods. The performance of the composite structural system is evaluated through explicit finite element analysis of shell elements carried out using LS-DYNA. Results from numerical examples demonstrate that optimization design processes can significantly improve composite part performance through implementation of optimum material layup and part shape. / Dissertation/Thesis / Masters Thesis Civil and Environmental Engineering 2014

abstract: The football helmet is a device used to help mitigate the occurrence of impact-related traumatic (TBI) and minor traumatic brain injuries (mTBI) in the game of American football. The current design methodology of using a hard shell with an energy absorbing liner may be adequate for minimizing TBI, however it has had less effect in minimizing mTBI. The latest research in brain injury mechanisms has established that the current design methodology has produced a helmet to reduce linear acceleration of the head. However, angular accelerations also have an adverse effect on the brain response, and must be investigated as a contributor of brain injury. To help better understand how the football helmet design features effect the brain response during impact, this research develops a validated football helmet model and couples it with a full LS-DYNA human body model developed by the Global Human Body Modeling Consortium (v4.1.1). The human body model is a conglomeration of several validated models of different sections of the body. Of particular interest for this research is the Wayne State University Head Injury Model for modeling the brain. These human body models were validated using a combination of cadaveric and animal studies. In this study, the football helmet was validated by laboratory testing using drop tests on the crown of the helmet. By coupling the two models into one finite element model, the brain response to impact loads caused by helmet design features can be investigated. In the present research, LS-DYNA is used to study a helmet crown impact with a rigid steel plate so as to obtain the strain-rate, strain, and stress experienced in the corpus callosum, midbrain, and brain stem as these anatomical regions are areas of concern with respect to mTBI. / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2014

abstract: Skin electronics is one of the most promising applications of stretchable electronics. The versatility of skin electronics can only be guaranteed when it has conformal contact with human skin. While both analytical and numerical solutions for contact between serpentine interconnects and soft substrate remain unreported, the motivation of this thesis is to render a novel method to numerically study the conformability of the serpentine interconnects. This thesis explained thoroughly how to conduct finite element analysis for the conformability of skin electronics, including modeling, meshing method and step setup etc.. User-defined elements were implemented to the finite element commercial package ABAQUS for the analysis of conformability. With thorough investigation into the conformability of Fermat’s spiral, it has been found that the kirigami based pattern exhibits high conformability. Since thickness is a key factor to design skin electronics, the thesis also talked about how the change of thickness of the skin electronics impacts on the conformability. / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2015

A challenge in engineering coupling design is the understanding of performance of contact geometry for a given application. “Wear” is one of a number of mechanical failures that can occur in mechanical coupling design. “Fretting wear” occurs where surfaces in contact are subjected to oscillating load and very small relative motion over a period of time. Fretting has been observed in many mechanical interactions and is known to be a reason for failure in many designs. Recent evidence suggests that fretting wear occurs at the taper junction of modular total hip replacements and leads to failure of the implants. Experimental testing to determine the wear behaviour that occurs in mechanical devices is time consuming, expensive and complicated. Computational wear modelling is an alternative method which is faster and cheaper than real testing and can be used in addition to testing to help improve component design and enhance wear characteristics. Developing an algorithm that can accurately predict fretting wear considering linear wear, volumetric wear and surface wear damage is the main focus of this thesis. The thesis proposes a new computational methodology incorporating published wear laws into commercial finite element code to predict fretting wear which could occur at the taper junction of total hip replacements. The assessment of wear in this study is solely based on mechanical wear (fretting) as being the primary mechanism causing surface damage. The method is novel in that it simulates the weakening of the initial taper ‘fixation’ (created at impaction of the head onto the stem in surgery) due to the wearing process. The taper fixation is modelled using a contact analysis with overlapped meshes at the taper junction. The reduction in fixation is modelled by progressive removal of the overlap between components based on calculated wear depth and material loss. The method has been used for three different studies to determine surface wear damage, linear and volumetric wear rates that could occur at taper junction of total hip replacements over time. The results obtained are consistent with those found from observation and measurement of retrieved prostheses. The fretting wear analysis approach has been shown to model the evolution of wear effectively; however, it has been shown that accurate, quantitative values for wear are critically dependant on mesh refinement, wear fraction and scaling factor, wear coefficient used and knowledge of the device loading history. The numerical method presented could be used to consider the effect of design changes and clinical technique on subsequent fretting wear in modular prosthetic devices or other mechanically coupled designs.