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.

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[pt] A soldagem é um processo de união de materiais que possui grande aplicação em diversos setores da indústria, como automotiva, óleo e gás, nuclear, naval, dentre outros. Dentre os fatores responsáveis pelo comprometimento da vida útil pós-soldagem de componentes mecânicos e estruturais se destacam as tensões residuais, cuja análise qualitativa e quantitativa é de extrema importância no projeto, na garantia da qualidade e prevenção de falhas de estruturas soldadas. No presente trabalho aplicou-se uma metodologia composta por análise numérica e experimental, que se complementaram. Chapas do aço AISI 1020 foram soldadas pelo processo Metal Active Gas (MAG), em um único passe. Os experimentos foram conduzidos com duas velocidades, visando avaliar a influência deste parâmetro sobre o nível das tensões residuais geradas. Na sequência, as tensões residuais foram analisadas por difração de raios-X. Simultaneamente, procedeu-se a análise numérica das tensões residuais, com o emprego do código comercial de elementos finitos ANSYS, através de um modelo sólido 3D, em análise não linear termo-elastoplástica, utilizando-se a técnica Birth and Death, ativando e desativando os elementos, à medida que o cordão de solda foi depositado. Parâmetros experimentais da soldagem, geometria das amostras, coeficiente de transmissão de calor, propriedades térmicas e mecânicas do material, que variam com a temperatura, foram utilizados como dados de entrada no modelo numérico. Por fim, realizou-se a comparação entre as tensões residuais determinadas experimentalmente por difração de raios-X e as calculadas numericamente pelo método de elementos finitos, observando-se uma boa concordância entre os resultados obtidos pelas duas metodologias. / [en] Welding is a process of joining materials that have wide application in various industry sectors such as automotive, oil and gas, nuclear, naval, among others. Residual Stresses is often a cause of premature failure of critical components. The qualitative and quantitative analysis of residual stresses is extremely important in the design, on quality assurance and prevention of weldment failures. The objective of this study was developing a methodology that includes numerical and experimental analyses that are complementary. AISI 1020 steel samples were butt welded by GMAW process with weld metal in a single pass. Experiments were conducted at different heat source speeds in order to evaluate the influence of this parameter on the level of residual stresses generated. Subsequently, the samples were subjected to measurement of residual stress by diffraction X-ray method. Simultaneously, a numerical analysis of the residual stresses was performed with a commercial finite element software called ANSYS (17.0), and a 3D solid model for a nonlinear thermo-elastic-plastic analysis using the Birth and Death technique, where the elements are enabled and disabled along weld metal deposition. Experimental welding parameters such as geometry of the samples, heat transfer coefficients, thermal and mechanical properties which vary with temperature were used as input data in the numerical model. Finally, there was a comparison between the residual stresses determined experimentally by diffraction of X-rays and computed data by finite element method. A good agreement was observed between the two methods.

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Made available in DSpace on 2014-10-09T12:42:06Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:05:54Z (GMT). No. of bitstreams: 0 / As ligas à base de níquel de alta resistência são utilizadas em uma infinidade de sistemas avançados, onde baixo peso e sistemas de transmissão mecânica de alta densidade de energia são necessários. Componentes, tais como, engrenagens, rolamentos e eixos poderiam ser consideravelmente menor e mais durável se uma grande melhoria em propriedades mecânicas de ligas à base de níquel for alcançada. Um refinamento significativo no tamanho de grão (incluindo nível nano) é um método promissor para a obtenção de melhorias fundamentais nas propriedades mecânicas. O tamanho de grão é conhecido por ter um efeito significativo sobre o comportamento mecânico dos materiais. Um dos métodos mais favoráveis de alcançar refinamento de grão extremo é submetendo os materiais à deformação plástica intensa. As principais variáveis microestruturais nas superligas são a quantidade de precipitados e sua morfologia, o tamanho e a forma do grão e a distribuição de carbonetos (Cr7C3 e Cr23C6) que poderão reduzir propriedades mecânicas da liga. Neste trabalho é apresentada análise por microscopia óptica e eletrônica de transmissão e também os dados de dureza após deformação plástica intensa (tensão de cisalhamento puro) e alguns tratamentos térmicos. / Dissertação (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN-CNEN/SP

A soldagem é o processo de união mais utilizado na fabricação de equipamentos pela indústria mecânica. Devido à introdução de calor durante o processo de soldagem, dependente do posicionamento da tocha e consequentemente do tempo, dilatações e contrações não uniformes produzem tensões térmicas no componente em questão, as quais permanecem como residuais ao final do processo, ao se atingir o equilíbrio térmico. O entendimento da formação e comportamento destas tensões se torna importante, pois na presença de carregamentos externos, a integridade estrutural do elemento mecânico pode ser comprometida. Portanto, este estudo visa analisar o comportamento destas tensões térmicas, avaliando ao final a magnitude e distribuição das tensões residuais, tendo como ferramenta o método dos elementos finitos. Inicialmente são apresentados os principais processos de soldagem envolvendo a fusão de materiais por meio de arco elétrico, sendo possível com base em uma explicação teórica, observar e entender a formação das tensões oriundas destes processos. Na sequência uma revisão bibliográfica contendo as principais técnicas para modelamento deste problema pelo método dos elementos finitos é apresentada, navegando por conceitos da análise térmica, que envolve o estudo das temperaturas e mecânica, a qual avalia as tensões formadas. Com toda parte teórica consolidada, um caso exemplo é analisado, simulando desta maneira um processo GTAW pelo programa computacional ANSYS, e comparando os resultados numéricos com os dados experimentais e numéricos obtidos na literatura. Ao final da simulação conclui-se que o modelo analisado reproduz fielmente a distribuição de temperaturas durante o processo e também estima corretamente as tensões residuais na chapa soldada, mostrando que a simulação de processos de soldagem utilizando o método dos elementos finitos se apresenta como uma ferramenta alternativa a indústria no aprimoramento de processos existentes ou desenvolvimento de novos. / Welding is the most used joining process in equipment manufacture by mechanical industry. Due to heat application during welding, varying with torch position and therefore by time, non-uniform expansion and contraction produces thermal stresses, which remains as residual when the component reaches thermal equilibrium. Formation and behavior of these stresses understanding becomes important since on external forces presence the mechanical piece may have it structural integrity compromised. This study aims to analyze thermal stress behavior due to welding evaluating residual stress magnitude and distribution at the process end by the finite element method. First of all fusion welding process by an electric arc are presented and a theoretical explanation about thermal stresses formation during welding is shared. Next is shown a bibliographic research with main techniques to model these problems using the finite element method, including thermal analysis, which involves temperature distribution study, and structural analysis that evaluate resulting stresses. With all theoretical background consolidated an example case of a GTAW process is studied utilizing ANSYS software, comparing numerical results with experimental and numerical data obtained in literature. It is possible to conclude that analyzed model accurately reproduces temperature distribution and also residual stress in the welded specimen proving that a welding process simulation via finite element method is an alternative tool for industry purposes on improving existing process and developing new ones.

Orientador: Louis Bernard Klaczko / Tese (doutorado) - Universidade Estadual de Campinas, Insituto de Biologia / Made available in DSpace on 2018-08-04T02:57:08Z (GMT). No. of bitstreams: 1 Araripe_LucianaOrdunha_D.pdf: 1442005 bytes, checksum: 69889cecab16cb4c8feae92d4eb04c7e (MD5) Previous issue date: 2005 / Resumo: A espécie Zaprionus indianus expandiu sua distribuição geográfica recentemente, a partir da invasão do continente sul-americano. O primeiro registro data de apenas seis anos, e acredita-se que a origem seja sul-africana. Hoje, indivíduos dessa espécie são encontrados numa amplitude latitudinal de 35o, do Uruguai a Belém (Brasil). A chegada de Z. indianus no Brasil apresenta uma oportunidade rara de se estudar um evento de invasão desde seu início. O estudo de características fisiológicas, morfológicas e genéticas de populações brasileiras pode ajudar a construir hipóteses para o sucesso de Z. indianus nas etapas de invasão, além de indicar o potencial para evolução e diferenciação fenotípica. Um aspecto fisiológico estudado nesta tese foi a condição reprodutiva em machos que foram submetidos a extremos de temperatura ao longo de seu desenvolvimento. O estresse térmico causa esterilidade nos machos e a investigação dos limites (superior e inferior) da curva de fertilidade relativa à temperatura, complementa os dados de viabilidade na caracterização do potencial de ocupação de áreas novas por espécies cosmopolitas. Quanto à morfologia, um aspecto estudado foi o dimorfismo sexual no número de cerdas abdominais em uma população africana. Dimorfismo sexual para este caráter foi observado em várias espécies em estudos anteriores, embora padrões diferentes tenham sido encontrados. Nesta tese o padrão observado em Z. indianus foi comparado com o de outra espécie cosmopolita, Drosophila melanogaster. Um terceiro ponto abordado nesta tese foi a investigação de 10 populações brasileiras quanto à variação fenotípica (tamanho e forma da asa). Além das diferenças entre populações, uma abordagem interessante é o quanto de variação está presente dentro de cada população. Ainda, é importante saber o quanto dessa variação é herdável para estimarmos qual a capacidade evolutiva da população. O estudo revelou a ocorrência de alta variabilidade fenotípica dentro e entre populações, além de variação genética aditiva suficiente para promover a evolução de caracteres relacionados à forma da asa / Abstract: The species Zaprionus indianus has recently expanded its geographical distribution with the invasion of the South American continent. The first record dates of only six years, and the origin is probably the South Africa. Nowadays, individuals of this species can be found in a latitudinal range of 35o, from Uruguai to Belém (Brazil). The arrival of Z. indianus in Brazil presents a rare opportunity of studying an event of invasion from its beginning. The study of physiological, morphological and genetic traits in Brazilian populations may contribute to generate hypothesis for the success of Z. indianus in the stages of invasion. Also, it may indicate the potential for evolution and phenotypic differentiation. One physiological trait studied in the current thesis was the relationship of fertility and the temperature of development. Extreme temperatures cause sterility in males and the study of the limits (upper and lower) of the fertility curve complements the data on viability for the characterization of the potential of cosmopolitan species to occupy new areas. One morphological character studied was the sexual dimorphism for the number of abdominal bristles in one African population. A significant sexual dimorphism for this trait was observed in several species in previous studies, though different patterns have been found. In the current work the pattern observed in Z. indianus was compared to the pattern for another cosmopolitan species, Drosophila melanogaster. The third approach of this thesis was the study of the phenotypic variation (size and shape of the wing) present in 10 Brazilian populations. Besides the differences among populations, an interesting approach is the amount of variation present within each population. Also, it is important to know the proportion of this variation that is heritable, which allows an estimate of the evolutionary potential of the population. This study revealed the occurrence of high phenotypic variability within and between populations. In addition, enough additive genetic variation exists to promote the evolution of traits related to the shape of the wing / Doutorado / Genetica Animal e Evolução / Doutor em Genetica e Biologia Molecular

Thermal stresses can arise in glass used in architectonic realisations in buildings as a result of solar irradiation:  that is, sunlight.  The magnitude of these thermal stresses depends on the temperature conditions in the glass in terms of the temperature differences between warm and cold areas.  The work described here has verified the existence and distribution of thermal stresses in glass, both theoretically and experimentally, in a load-bearing element made of glass and wood, when exposed to incident solar radiation and various degrees of shading.  The finite element method was used in order to simulate the temperature distribution in the glass, together with the resulting associated thermal stresses.  Parts of these model results were then compared with results and data from experimental investigations in a solar simulator.  The experimental trials were carried out on a plain glass sheet and on a wood-framed glass sheet.  This frame assembly saw the glass fitted in a wooden frame such that its edge was flush with the edges of the frame and therefore freely exposed to the surroundings.  Two different grades of glass were analysed in the theoretical modelling and used in the experimental solar exposure:  a clear glass, with a low absorption coefficient, and a tinted glass having a relatively high absorption coefficient.  The experimental part of the work included two different finishes to the glass edge:  as-cut, with no further attention, and cut and smoothed.  The results from the finite element method calculations agree relatively well with the experimental results.  When simulating the temperature values and distributions, the value of the coefficient of heat transfer is an important factor in determining the results.  The coefficient can be given either a constant value, taken from a standard, or a calculated value that varies depending on the surface temperature and ambient temperature at every instant.  For the clear glass with a low coefficient of absorption, the calculated temperatures did not differ significantly depending on which method had been used to provide a value for the coefficient of heat transfer.  However, for the glass with a high coefficient of absorption, and when exposed to high solar intensity, a calculated value of coefficient of heat transfer should be used in order to arrive at relevant values of surface temperatures and stresses.  Thermal tensile stresses have more effect on the total stress level than have stresses arising from typical in-service vertical loads.

Au cours des deux dernières décennies, l'essai d'indentation à haute température a été développé progressivement afin de satisfaire aux exigences industrielles de plus en plus importantes. Pour garantir un bon niveau de précision des mesures, il faut résoudre les problèmes notamment associés à la température élevée tels que le choix du matériau de la pointe, la stabilité thermique du système, la conception du chauffage, etc. Cette thèse s'inscrit dans la problématique du développement de la méthodologie de l'essai d'indentation à haute température pour caractériser les matériaux métalliques. Une attention particulière a été accordée à la recherche des matériaux candidats pour la pointe et à la détermination des plages de forces et de pénétrations utilisées au bon fonctionnement d'un indenteur. Les analyses éléments finis nous aident d'étudier l'influence de défauts tels que la présence d'un revêtement mince et celle d'un défaut d'alignement entre l'axe d'indentation et la surface d'échantillon. Pour trouver un bon matériau de pointe, il est nécessaire de tester la stabilité géométrique et chimique de différents matériaux candidats pouvant remplacer le diamant à haute température. La collaboration avec la société suisse Anton Paar, qui se spécialise dans la fabrication des machines de mesure pour la caractérisation mécanique d'une grande variété de matériaux, permet de développer un nouvel équipement de micro- et nano-indentation à haute température. En utilisant le nouvel dispositif, nous avons pu réaliser des essais d'indentation pour caractériser des propriétés mécaniques de différents matériaux et vérifier la stabilité thermique de cet instrument. / Over the past two decades, the high-temperature indentation experiment has been developed gradually to meet increasingly high industrial demand. ln order to guarantee a good level of accuracy of the measurements, it is necessary to solve the problems associated with high temperature, such as the choice of the indenter material, the thermal stability of the system, heating design, etc. This thesis aims to develop the methodology of the high-temperature indentation experiment to characterize metallic materials. Particular attention has been given to the search for candidate materials for the tip and to the determination of the force and penetration ranges used for the correct operation of an indenter. The finite element analysis helps us to study the influence of defects such as the presence of a thin film and that of a misalignment between the indentation axis and the sample surface. To find a better indenter material, it is necessary to test the geometric and chemical stability of different candidate materials that can replace the diamond at elevated temperature. The collaboration with the Swiss company Anton Paar, which specializes in the manufacture of measuring machines for the mechanical characterization of a wide variety of materials, enables the development of new high-temperature micro- and nano­-indentation equipment. By using the new device, we were able to carry out the indentation tests to characterize the mechanical properties of different materials and to check the thermal stability of this new instrument.