Search Results (192)

While material extrusion via fused filament fabrication (FFF) offers design flexibility and rapid prototyping, its practical use in engineering is limited by mechanical challenges, including residual stresses, geometric distortions, and potential interlayer debonding. These issues arise from the dynamic thermal profiles during FFF, including temperature gradients, non-uniform hardening, and rapid thermal cycling, which lead to uneven internal stress development depending on fabrication parameters and object topology. These problems can compromise the structural integrity and mechanical properties of FFF parts, especially when the load-bearing capacity and geometric accuracy are critical. This study focuses on polylactic acid (PLA) due to its widespread application in engineering. It introduces a computational framework for coupled thermo-mechanical simulations of the FFF process using ABAQUS (Version 2020) finite element software. A key innovation is an automated subroutine that converts G-code into a time-resolved event series for finite element activation. The simulation framework explicitly models the sequential stages of printing, cooling, and detachment, enabling prediction of adhesive loss and post-process warpage. A transient thermal model evaluates the temperature distribution during FFF, providing boundary conditions for a mechanical simulation that predicts residual stresses and warping. Uniquely, the proposed model incorporates the detachment stage, enabling a more realistic and experimentally validated prediction of warpage and residual stress release in FFF-fabricated components. Although the average deviation between predicted and measured displacements is about 10.6%, the simulation adequately reflects the spatial distribution and magnitude of warpage, confirming its practical usefulness for process optimization and design validation. Full article

The main purposes of the present paper are to present the mathematical and algorithmic aspects of the ANM/FEM numerical model and to show how it is applied to analyze elastic and thermo-elastic nonlinear solid mechanical problems. ANM is a robust continuation method based on a perturbation technique for solving nonlinear problems dependent on a loading parameter. Historically, this technique has been successfully applied to problems in various fields of solid and fluid mechanics. This paper shows how ANM is used to solve nonlinear elastic and nonlinear thermo-elastic problems involving elastic behavior and geometrical nonlinearities. The implementation of ANM for FEM in the FreeFEM++ language is then presented. The FEM software development platform, called FreeFEM++, is structured to work with variational formulations and, therefore, is well adapted to implement ANM for instability problems in solid mechanics. In order to illustrate the great efficiency of FreeFEM++, scripts will be presented for computing the different steps of ANM continuation for solid elastic structures, considering simple geometries subjected to conservative loading. For the purpose of validation, the problem of a cantilever subjected to an applied force is presented. Next, the new numerical model is applied to study wrinkles appearing in a planar film/substrate system that is subjected to compressive surface forces at the lateral faces of the film. Finally, the model is applied to a spherical film/substrate system subjected to thermo-elastic shrinkage. In both cases, the ANM/FEM prediction method, together with a Newton–Riks correction (if needed), identifies the equilibrium paths efficiently, especially after the post-buckling regime. Full article

Fiber orientation is an important descriptor of the microstructure for short fiber polymer composite materials where accurate and efficient prediction of the orientation state is crucial when evaluating the bulk thermo-mechanical response of the material. Macroscopic fiber orientation models employ the moment-tensor form in representing the fiber orientation state, and they all require a closure approximation for the higher-order orientation tensors. In addition, various models have more recently been developed to account for rotary diffusion due to fiber-fiber and fiber-matrix interactions which can now more accurately simulate the experimentally observed slow fiber kinematics in polymer composite processing. It is common to use explicit numerical initial value problem-ordinary differential equation (IVP-ODE) solvers such as the 4th- and 5th-order Dormand Prince Runge–Kutta (RK45) method to predict the transient and steady-state fiber orientation response. Here, we propose a computationally efficient method based on the Newton-Raphson (NR) iterative technique for determining steady state orientation tensor values by evaluating exact derivatives of the moment-tensor evolution equation with respect to the independent components of the orientation tensor. We consider various existing macroscopic-fiber orientation models and several closure approximations to ensure the robustness and reliability of the method. The performance and stability of the approach for obtaining physical solutions in various homogeneous flow fields is demonstrated through several examples. Validation of our orientation tensor exact derivatives is performed by benchmarking with results of finite difference techniques. Overall, our results show that the proposed NR method accurately predicts the steady state orientation for all tensor models, closure approximations and flow types considered in this paper and was relatively faster compared to the RK45 method. The NR convergence and stability behavior was seen to be sensitive to the initial orientation tensor guess value, the fiber orientation tensor model type and complexity, the flow type and extension to shear rate ratio. Full article

To address the central cracking problem in continuous casting slabs of 38CrMoAl steel, high-temperature tensile tests were performed using a Gleeble-3800 thermal simulator to characterize the hot ductility of the steel within the temperature range of 600–1200 °C. The phase transformation behavior was computationally analyzed via the Thermo-Calc software, while the microstructure, fracture morphology, and precipitate characteristics were systematically investigated using a metallographic microscope (MM), a field-emission scanning electron microscope (FE-SEM), and transmission electron microscopy (TEM). Additionally, the effects of different holding times and cooling rates on the microstructure and precipitates of 38CrMoAl steel were also studied. The results show that the third brittle temperature region of 38CrMoAl steel is 645–1009 °C, and the fracture mechanisms can be classified into three types: (I) in the α single-phase region, the thickness of intergranular proeutectoid ferrite increases with rising temperature, leading to reduced hot ductility; (II) in the γ single-phase region, the average size of precipitates increases while the number density decreases with increasing temperature, thereby improving hot ductility; and (III) in the α + γ two-phase region, the precipitation of proeutectoid ferrite promotes crack propagation and the dense distribution of precipitates at grain boundaries causes stress concentration, further deteriorating hot ductility. Heat treatment experiments indicate that the microstructures of the specimen transformed under water cooling, air cooling, and furnace cooling conditions as follows: martensite + proeutectoid ferrite → bainite + ferrite → ferrite. The average size of precipitates first decreased, then increased, and finally decreased again with increasing holding time, while the number density exhibited the opposite trend. Therefore, when the holding time was the same, reducing the cooling rate could increase the average size of the precipitates and decrease their number density, thereby improving the hot ductility of 38CrMoAl steel. Full article

This paper presents a theoretical model of a thin, penny-shaped piezoelectric actuator bonded to an isotropic thermo-elastic substrate under coupled electrical-thermal-diffusive loading. The problem is assumed to be axisymmetric, and the peeling stress of the film is neglected in accordance with membrane theory, yielding a simplified equilibrium equation for the piezoelectric film. By employing potential theory and the Hankel transform technique, the surface strain of the substrate is analytically derived. Under the assumption of perfect bonding, a governing integral equation is established in terms of interfacial shear stress. The solution to this integral equation is obtained numerically using orthotropic Chebyshev polynomials. The derived results include the interfacial shear stress, stress intensity factors, as well as the radial and hoop stresses within the system. Finite element analysis is conducted to validate the theoretical predictions. Furthermore, parametric studies elucidate the influence of material mismatch and actuator geometry on the mechanical response. The findings demonstrate that, the performance of the piezoelectric actuator can be optimized through judicious control of the applied electrical-thermal-diffusive loads and careful selection of material and geometric parameters. This work provides valuable insights for the design and optimization of piezoelectric actuator structures in practical engineering applications. Full article

Static analysis is conducted for functionally graded material (FGM) spherical shells under thermo-mechanical loads, based on the three-dimensional thermo-elasticity theory. The material properties, which vary with both the radial coordinate and temperature, introduce nonlinearity to the problem. To address this, a layer model is proposed, wherein the shell is discretized into numerous concentric spherical layers, each possessing uniform material properties. Within this framework, the nonlinear heat conduction equations are first solved iteratively. The resulting temperature field is then applied to the thermo-elastic equations, which are subsequently solved using a combined state space and transfer matrix method to obtain displacement and stress solutions. Comparison with existing literature results demonstrates good agreement. Finally, a parametric study is presented to investigate the effects of material temperature dependence and gradient index on the thermo-mechanical behaviors of the FGM spherical shells. Full article

A meshless, quasi-convex reproducing kernel particle framework for three-dimensional steady-state thermomechanical coupling problems is presented in this paper. A meshfree, second-order, quasi-convex reproducing kernel scheme is employed to approximate field variables for solving the linear Poisson equation and the elastic thermal stress equation in sequence. The quasi-convex reproducing kernel approximation proposed by Wang et al. to construct almost positive reproducing kernel shape functions with relaxed monomial reproducing conditions is applied to improve the positivity of the thermal matrixes in the final discreated equations. Two numerical examples are given to verify the effectiveness of the developed method. The numerical results show that the solutions obtained by the quasi-convex reproducing kernel particle method agree well with the analytical ones, with a slightly better-improved numerical accuracy than the element-free Galerkin method and the reproducing kernel particle method. The effects of different parameters, i.e., the scaling parameter, the penalty factor, and node distribution on computational accuracy and efficiency, are also investigated. Full article

A physical and mathematical model and a methodology for studying the mechanical properties of a nonferromagnetic conductive panel under the action of a quasi-steady electromagnetic field are proposed. A two-dimensional thermomechanics problem is formulated for the considered panel of a rectangular cross-section. The initial relations for finding the determinant functions, namely, the components of the quasi-static stress tensor, are given. The thermomechanical problem was addressed using the author’s approach, which involves approximating the defining functions by cubic polynomials along the thickness direction. This approach enabled the transformation of the initial two-dimensional boundary value problems into one-dimensional formulations based on the integral characteristics of the defining functions. Using a finite integral transformation in the transverse coordinate, the expressions of all integral characteristics and determinant functions were obtained. On the basis of the proposed mathematical model, a computer analysis of all components of the quasi-static stress tensor and stress intensity in a tungsten panel depending on the dimensionless Fourier time, the Biot criterion, and the induction heating parameters was carried out. The thermomechanical behavior of the panel was analyzed using two modes of near-surface and in-depth induction heating of the panel by a homogeneous quasi-steady electromagnetic field. Full article

This paper focuses on the use of advanced optimization design strategies to improve the performance and service life of engine pistons, with emphasis on enhancing their stiffness, strength, and dynamic characteristics. As a core component of the engine, the structural design and optimization of the piston are of great significance to its efficiency and reliability. First, a three-dimensional (3D) model of the piston was constructed and imported into ANSYS Workbench for finite element modeling and high-quality meshing. Based on the empirical formula, the actual working environment temperature and heat transfer coefficient of the piston were accurately determined and used as boundary conditions for thermomechanical coupling analysis to accurately simulate the thermal and deformation state under complex working conditions. Dynamic characteristic analysis was used to obtain the displacement–frequency curve, providing key data support for predicting resonance behavior, evaluating structural strength, and optimizing the design. In the optimization stage, five geometric dimensions are selected as design variables. The deformation, mass, temperature, and the first to third natural frequencies are considered as optimization goals. The response surface model is constructed by means of the design of the experiments method, and the fitted model is evaluated in detail. The results show that the models are all significant. The adequacy of the model fitting is verified by the “Residuals vs. Run” plot, and potential data problems are identified. The “Predicted vs. Actual” plot is used to evaluate the fitting accuracy and prediction ability of the model for the experimental data, avoiding over-fitting or under-fitting problems, and guiding the optimization direction. Subsequently, the sensitivity analysis was carried out to reveal the variables that have a significant impact on the objective function, and in-depth analysis was conducted in combination with the response surface. The multi-objective genetic algorithm (MOGA), screening, and response surface methodology (RSM) were, respectively, used to comprehensively optimize the objective function. Through experiments and analysis, the optimal solution of the MOGA algorithm was selected for implementation. After optimization, the piston mass and deformation remained relatively stable, and the working temperature dropped from 312.75 °C to 308.07 °C, which is conducive to extending the component life and improving the thermal efficiency. The first to third natural frequencies increased from 1651.60 Hz to 1671.80 Hz, 1656.70 Hz to 1665.70 Hz, and 1752.90 Hz to 1776.50 Hz, respectively, significantly enhancing the dynamic stability and vibration resistance. This study integrates sensitivity analysis, response surface models, and genetic algorithms to solve multi-objective optimization problems, successfully improving piston performance. Full article

This study proposes an RBF-PSO hybrid framework for efficient inversion analysis of hydration heat parameters in mass concrete temperature fields, addressing the computational inefficiency and accuracy limitations of traditional methods. By integrating a Radial Basis Function (RBF) surrogate model with Particle Swarm Optimization (PSO), the method reduces reliance on costly finite element simulations while maintaining global search capabilities. Three objective functions—integral-type (F₁), feature-driven (F₂), and hybrid (F₃)—were systematically compared using experimental data from a C40 concrete specimen under controlled curing. The hybrid F₃, incorporating Dynamic Time Warping (DTW) for elastic time alignment and feature penalties for engineering-critical metrics, achieved superior performance with a 74% reduction in the prediction error (mean MAE = 1.0 °C) and <2% parameter identification errors, resolving the phase mismatches inherent in F₂ and avoiding F₁’s prohibitive computational costs (498 FEM calls). Comparative benchmarking against non-surrogate optimizers (PSO, CMA-ES) confirmed a 2.8–4.6× acceleration while maintaining accuracy. Sensitivity analysis identified the ultimate adiabatic temperature rise as the dominant parameter (78% variance contribution), followed by synergistic interactions between hydration rate parameters, and indirect coupling effects of boundary correction coefficients. These findings guided a phased optimization strategy, as follows: prioritizing high-precision calibration of dominant parameters while relaxing constraints on low-sensitivity variables, thereby balancing accuracy and computational efficiency. The framework establishes a closed-loop “monitoring-simulation-optimization” system, enabling real-time temperature prediction and dynamic curing strategy adjustments for heat stress mitigation. Robustness analysis under simulated sensor noise (σ ≤ 2.0 °C) validated operational reliability in field conditions. Validated through multi-sensor field data, this work advances computational intelligence applications in thermomechanical systems, offering a robust paradigm for parameter inversion in large-scale concrete structures and multi-physics coupling problems. Full article

The simulation of additive manufacturing processes, such as Wire Arc Additive Manufacturing (WAAM), is becoming increasingly important to predict material and component properties in advance of the real-life manufacturing. In contrast to prior work focusing on the simulation of simplified WAAM parts, this paper presents an investigation into the thermo-mechanical finite element (FE) simulation of the manufacturing of large-scale WAAM components. The investigation focuses on various problems within the individual steps of the FE workflow wherein ABAQUS influences the modeling of large-scale components. The investigations are founded upon a thermo-mechanically coupled FE model in ABAQUS 2020. For this purpose, several thermo-mechanical simulation models are set up with the target of investigating the meshing, element activation and variation of process parameters. Appropriate discretization of WAAM components is found to be a major problem when setting up a simulation. The meshing of the component is limited by the element type and size and the meshing routines used. Also, differences in the axes of motion for the simulation and the real process cause the simulation to differ from reality. High element start temperatures are found to be beneficial for simulation stability and performance. An integrated parameter variation was made possible with the modeling techniques used. Full article

A two-dimensional physical and mathematical model is proposed for determining the components of the stress tensor and stress intensity in an electroconductive plate of rectangular cross-section under the action of an unsteady electromagnetic field. The two-dimensional thermomechanics problem for such a plate is formulated. The determining functions are the component of the magnetic field intensity vector tangent to the plate bases, temperature, and components of the stress tensor. The methodology for solving the formulated thermomechanics problem by approximating all the determining functions by the thickness variable with cubic polynomials is developed. As a result, the original two-dimensional problems related to the determining functions are reduced to one-dimensional problems on the integral characteristics of these functions. To solve the obtained systems of equations for the integral characteristics of the determining functions, a finite integral transformation in the transverse variable is used. During induction heating of a copper plate by a homogeneous quasi-steady-state electromagnetic field, the change in the stress intensity depending on the Fourier time, as well as its distribution across the plate cross-section depending on the parameters of induction heating and the Biot criterion, is numerically analyzed. Full article

A numerical model to simulate the laser thermoforming process (LTF) is proposed. It is developed on the basis of the thermodynamically consistent theory of coupled thermo-viscoplasticity and is suitable for modeling the LTF for thin-walled metal structural elements. In the frame of this model, the problem statement consists of the Cauchy relation, equations of motion, and the energy balance equation, which is reduced to the heat conduction equation, along with mechanical and thermal boundary conditions, as well as initial conditions. To describe the behavior of the material, a generalized model of physically nonlinear temperature-dependent thermo-viscoplasticity is used. Spatial discretization of the axisymmetric problem of laser pulse loading of the disk is performed by the FEM. The unsteady LTF process of the deformed disk configuration is simulated. The final profile of the disk is obtained as a result of a thermally induced residual stress–strain state caused by the rapid heating and subsequent gradual cooling of the material under the laser-irradiated area. Full article

The thermal protection system of a re-entry vehicle requires a high-heat-resistant heat shield to protect the spacecraft. Most of the ablative materials developed so far have high heat resistance but have technical issues such as long production times. In this study, we propose a new ablative material (LATS/PEEK) consisting of PEEK and carbon felt as a material that can solve these problems. PEEK has excellent properties such as a short production time and its ability to be produced using 3D printer technology. In addition, PEEK can be molded with a variety of fusion bonding methods, so it is possible to mold the heat shield and structural components as a single structure. However, heating tests conducted in previous research have confirmed the expansion phenomenon of CF/PEEK produced by 3D printers. The expansion of the ablative material is undesirable because it changes the aerodynamic characteristics during re-entry flight. Therefore, the purpose of this research is to clarify the mechanism of the expansion phenomenon of the ablative material based on PEEK resin. Therefore, we conducted thermal gravimetric analysis (TGA) and thermomechanical analysis (TMA) and concluded that the expansion phenomenon during the heating test was caused by the pressure increase inside the ablative material due to pyrolysis gas. Based on this mechanism, we developed a new 3D LATS/PEEK with a structure that can actively release pyrolysis gas, and we conducted a heating test using an arc-heating wind tunnel. As a result, it was found that 3D LATS/PEEK had less expansion and deformation during the heating test than CF/PEEK manufactured using a 3D printer. Full article

In this study, a multi-physical and thermal–fluid–solid coupling model was developed to simulate the autoclave curing process of composite materials, aiming to explore the influence mechanism of the external flow field on the curing process. First, the extended layerwise method (XLWM) and finite volume method were adopted to simulate the composite laminates and heating airflows, respectively. Then, the thermo-chemical–mechanical-seepage analysis was carried out for the composite laminates. Considering the interaction between the airflows and laminates, a weak coupling method was proposed to solve the thermal–fluid–solid coupling problem, which consists of two parts: unidirectional coupling and bidirectional coupling. In numerical examples, the results of the two coupling schemes were compared, which indicated that the bidirectional coupling scheme consumed fewer computing resources but achieved similar accuracy. Full article