Use of an enriched shell finite element to simulate delamination-migration in a composite laminate
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Mark McElroy↗
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Improving Computational Efficiency of Mechanical Finite Element Method Simulations for PV Modules: Preprint
In this work we have elucidated the trade off between structural mechanics FEM model accuracy and computation time by employing lower fidelity viscoelastic models. Results indicate that computation time can easily be cut in half while only expecting a potential maximum error of 10 % by considering lower fidelity models. A novel approach to produce the Prony Series fit for viscoelastic characterization has also been presented. Employing this approach, we were able to achieve a further 10 % reduction in computation time without further sacrificing simulation accuracy.
41 EE - Solar Energy Technologies Office (EE-4S)↗
Identification Uncertainty in Inverse Material Model Parameter Determination: A Sensitivity‐Based Decision Process for Load Path Selection
This research proposes a sensitivity-based framework for selecting the optimal prescribed loading path for a biaxial cruciform specimen. Optimality here is determined by the direction and magnitude of the prescribed displacement that minimizes the influence of random noise on the material model parameter identification. Using simulated experimental data based on finite element simulation, in this work, we identify the material model parameters of a Ludwik hardening model and plane stress implementation of the Hill-48 yield criterion using finite element model updating (FEMU). Our analysis reveals that the identification (or estimator) uncertainty of model parameters depends on the displacement boundary conditions (i.e., loading sequence) and the ground-truth value of the individual parameters. Optimal experimental design (OED) criteria based on the Fisher information matrix were investigated to mitigate indecision in the choice of optimal load path when the identification uncertainty of different material model parameters optimized at different load paths. The determinant of the Fisher information matrix was chosen here as the more useful metric due to its ability to capture uncertainty of the most influential material model parameters. The proposed framework demonstrates potential for real-time automated load step selection using scalar criteria derived prior to mechanical loading. The framework can be generalized to other geometries, boundary conditions and material models, allowing this procedure to be utilized for different experimental configurations and materials.
Fayad, Samuel S. [University of Illinois at Urbana↗
An Approach to Assess Delamination Propagation Simulation Capabilities in Commercial Finite Element Codes
An approach for assessing the delamination propagation simulation capabilities in commercial finite element codes is presented and demonstrated. For this investigation, the Double Cantilever Beam (DCB) specimen and the Single Leg Bending (SLB) specimen were chosen for full three-dimensional finite element simulations. First, benchmark results were created for both specimens. Second, starting from an initially straight front, the delamination was allowed to propagate. The load-displacement relationship and the total strain energy obtained from the propagation analysis results and the benchmark results were compared and good agreements could be achieved by selecting the appropriate input parameters. Selecting the appropriate input parameters, however, was not straightforward and often required an iterative procedure. Qualitatively, the delamination front computed for the DCB specimen did not take the shape of a curved front as expected. However, the analysis of the SLB specimen yielded a curved front as was expected from the distribution of the energy release rate and the failure index across the width of the specimen. Overall, the results are encouraging but further assessment on a structural level is required.
Krueger, Ronald↗
An Investigation of Plume Response to Soil Vapor Extraction and Hypothetical Drum Failure
Core Ideas Soil vapor extraction (SVE) wells are an effective interim remediation technique. Flow and transport modeling assists in evaluation of vapor plume behavior. Plume simulations assuming drum failure and SVE provide a framework for remediation planning. A small borehole subset could be monitored for detection of VOC releases due to drum failure. Soil vapor extraction (SVE) has been used at sites across the Department of Energy complex, including sites where legacy subsurface wastes represent a potential source of groundwater contamination. At Los Alamos National Laboratory (LANL), leakage from waste drums buried at an inactive chemical waste site has created a subsurface vapor plume of volatile organic compounds (VOCs). Soil vapor extraction operation in 2015 and rebound testing through 2017 were successful in reducing the plume's mass and mitigating VOC migration toward the water table. However, the possibility that waste drums could fail and release VOCs could pose a challenge in the future. To explore the impacts of drum failure, as well as the capabilities of SVE remediation, we simulated hypothetical contaminant release scenarios and subsequent SVE remediation. Three‐dimensional subsurface VOC behavior, including advection, diffusion, and plume interactions with topography, were simulated using the porous flow simulator Finite Element Heat and Mass Transfer. Simulations of future site conditions have allowed identification of “sentry” boreholes that can be monitored for early detection in case of drum failure. Sentry boreholes can also be used to set concentration thresholds above which SVE should be initiated. For the LANL site, simulations show that SVE can be started 3 yr following drum failure and remain a viable remediation tool. More broadly, the principles outlined in this work can be used to support remediation planning at other subsurface waste sites. Predictive models of future releases can be analyzed to set concentration threshold values, guide selection of sentry boreholes, and increase operational efficiency.
54 ENVIRONMENTAL SCIENCES↗
Prelude to Simulation Diagnostics in MOOSE: Diagnosing Meshes
As finite element simulations increase in complexity, so does the need for high quality meshes. Without proper diagnostics, issues pertaining to poor mesh quality or improper mesh construction may go undetected, causing simulations to fail unexpectedly. This paper details the new mesh diagnostic system available in MOOSE, which provides users with the tools to inspect mesh quality for both externally and internally generated meshes. This system can detect issues arising from element volume size, non-conformal elements, intersecting edges, missing sidesets, as well as other common mesh issues. As meshes increase in size and complexity, such issues become more difficult to diagnose through visual inspection alone.
99 - GENERAL AND MISCELLANEOUS↗
Vertical Drop Test and Simulation of a Fokker F-28 Fuselage Section
In March 2017, a vertical drop test of a 3.048-m(10-ft) section of a Fokker F-28 aircraft was conducted as a part of a joint NASA/FAA effort to investigate the performance of transport aircraft under realistic crash conditions. The section was configured with two rows of aircraft seats, in a triple-double configuration. A total of ten Anthropomorphic Test Devices (ATDs) were secured in the seats using standard seat belt restraints. The section was also configured with luggage in the cargo hold. Two hat racks were added, each with mass loading of 37.2-kg per linear meter (25-lb/ft). The drop test was performed at the Landing and Impact Research facility located at NASA Langley Research Center in Hampton, Virginia. The planned impact velocity was 9.144-m/s (360-in/s) onto soil. A second objective was to assess the capabilities of finite element simulations to predict the test response. A finite element model was developed for execution in LS-DYNA, a commercial explicit nonlinear transient dynamic code. The model contained accurate representations of the airframe structure, the hat racks and hat rack masses, the floor and seat tracks, and the luggage in the cargo hold. Concentrated masses were used to represent the inertial properties of the seats, restraints, and ATD occupants. The model was executed to generate analytical predictions of airframe responses, which were compared with test data to validate the model.
Jackson, K. E.↗
Finite deformation implementation of a mixed-mode single-integral type cohesive zone with reorienting surfaces of separation
To model material ductile failure and crack propagation, cohesive zone elements can be embedded along potential fracture paths in a finite element simulation. When damage criteria are met, elements in the mesh decohere, simulating the formation and propagation of a crack. In this paper, we present a novel computational algorithm based on finite deformation theory, essential to modeling crack initiation and growth in solids undergoing large deformations. This new algorithm was formulated within a Lagrangian frame of reference to extend previous cohesive zone algorithms to include modeling crack growth in finite deformation contexts. The local coordinate system, necessary for defining an embedded cohesive zone, is constructed based upon the current configuration and is updated within the nonlinear iteration process, thereby resulting in the convergence of the solution for a growing crack in a large deformation quasi-static setting. The model’s accuracy was demonstrated by comparing finite element model simulation results with the analytic case of a constant surface separation, as shown in the verification examples. The power and efficacy of the algorithm to capture large deformations during crack growth were then demonstrated with a double cantilever beam example case. It indicates that the model can be applied to a variety of physical circumstances for predicting crack initiation and growth with delamination and fracture.
42 ENGINEERING↗
On Residual Stresses and Reference Temperatures in Thermomechanical Simulations of Photovoltaic Modules Using the Finite Element Method
Thermomechanical simulation of photovoltaic (PV) modules using the finite element method (FEM) is a useful tool to evaluate module design features in terms of structural integrity, reliability, and durability. One of the main challenges in the numerical modeling of a PV module is the incorporation of residual stresses induced by the manufacturing process. Modeling assumptions and abstractions are necessary to limit the model complexity and reduce the computational time. However, oversimplifications and incorrect assumptions can lead to erroneous numerical results. Unfortunately, much simulation work still neglects process-induced stresses. This can lead to incorrect predictions of the stress-strain history and erroneous conclusions during the design process. In this work, we review current modeling practices for incorporating process-induced stresses, and contrast numerical models that consider residual stresses with those that neglect them. We find that the simulation objective and available material properties dictate which process steps need to be modeled, and explore in depth the modeling of residual stresses induced by the lamination process. We demonstrate that a simplified cooldown procedure at the beginning of the simulation can increase the model accuracy and discuss appropriate choices for starting and reference temperatures in the finite element model.
14 SOLAR ENERGY↗
The influence of plasticity-induced crack closure on creep-fatigue crack growth in two heat-resistant steels
Finite element simulations are performed to predict plasticity-induced crack closure and creep-fatigue crack growth rates in two heat-resistant steels, the austenitic 20Cr-25Ni (Alloy 709) and martensitic 9Cr-1Mo (modified 1Cr-9Mo) steels. In a creep-fatigue cycle, total crack growth rate is usually computed by the addition of the fatigue crack growth rate during cyclic loading and creep crack growth rate during hold time. Two-dimensional finite element analyses of compact tension specimens are performed to simulate crack growth under cyclic and time-dependent loading conditions, with the consideration of elastic-plastic and creep deformations of the material at the crack tip. The simulations quantify the effect of hold time on crack opening load induced by the combined action of plasticity-induced crack closure and creep-induced stress relaxation at the crack tip. It is shown that increasing hold time during a creep-fatigue cycle results in a decrease of crack-tip opening load, thus increasing crack growth rate during the next cyclic loading. Experimental results of creep-fatigue crack growth rates in Alloy 709 are presented. The finite element simulations predicted crack growth rates under creep-fatigue loading in agreement with experimental values for both Alloy 709 and modified 9Cr-1Mo steels.
36 MATERIALS SCIENCE↗
Selective growth of Ni4Ti3 precipitate variants induced by complicated cyclic stress during laser additive manufacturing of NiTi-based composites
Highlights: • The NiTi-based composites were in-situ synthesized by SLM. • Ni{sub 4}Ti{sub 3} could tailor the phase transformation temperature of TiC/NiTi composites. • A three-dimensional stress field modeling of TiC/NiTi composites was established. • The relationship between growth of Ni{sub 4}Ti{sub 3} variants and cyclic stress was disclosed. - Abstract: NiTi-based composites were in-situ synthesized by selective laser melting (SLM) additive manufacturing technology with formation of a great many Ni{sub 4}Ti{sub 3} precipitates. The differential scanning calorimetry (DSC) were carried out to exhibit the similar phase transformation temperature (A{sub s} = 51.82 °C, A{sub f} = 94.02 °C, M{sub s} = 55.87 °C and M{sub f} = 18.93 °C) by comparing with that of SLM-fabricated equi-atomic NiTi alloy, which could be attributed to the compensation of Ni{sub 4}Ti{sub 3} precipitates for the effect of an addition of TiC particles. Three different Ni{sub 4}Ti{sub 3} precipitate variants ((111){sub R}//(1 1-bar 1-bar ){sub B2}, (111){sub R}//( 1-bar 1-bar 1){sub B2}, and (111){sub R}//( 1-bar 1 1-bar ){sub B2}) with various precipitate diameters were observed within SLM fabricated part, showing apparently selective growth behavior. By high-resolution transmission electron microscopy, severe lattice defects formed surrounding the smaller variant, while relatively intact lattice structure was found around the larger one, which indicated that high strain energy was produced in the interface between the matrix and the smaller variant. Furthermore, finite element simulation method was applied to disclose the evolution features of complicated cyclic stress during SLM processing of TiC/NiTi composites. By predicting, the main constraint mode within as-fabricated track was tensile stress effect. Based on the redistribution behavior of thermal stress and the coupling effect between the thermal stress and strain field induced by Ni{sub 4}Ti{sub 3} precipitate, the selective growth mechanism of Ni{sub 4}Ti{sub 3} variant was revealed.
36 MATERIALS SCIENCE↗
Strain Rate Dependency of Simulated Welding Residual Stresses
In the present work, the influence of taking into consideration the strain rate-dependent nature of steel S355 during a calculation of the welding residual stresses through a finite element simulation is investigated. The Perzyna material model is calibrated using experimental values found in the literature and is introduced to a validated weld simulation model, where the strain rate dependency had not been taken into consideration before this study. The calculated profiles of the welding residual stresses, for strain rate-dependent and independent behavior, are then compared with experimentally measured profiles. The results of this first-step analysis show that taking into consideration strain rate dependency during a welding simulation of the investigated S355 has non-negligible influence on the calculated welding residual stresses.
36 MATERIALS SCIENCE↗
Interfacing modules for integrating discipline specific structural mechanics codes
An outline of the organization and capabilities of the Engine Structures Computational Simulator (Simulator) at NASA Lewis Research Center is given. One of the goals of the research at Lewis is to integrate various discipline specific structural mechanics codes into a software system which can be brought to bear effectively on a wide range of engineering problems. This system must possess the qualities of being effective and efficient while still remaining user friendly. The simulator was initially designed for the finite element simulation of gas jet engine components. Currently, the simulator has been restricted to only the analysis of high pressure turbine blades and the accompanying rotor assembly, although the current installation can be expanded for other applications. The simulator presently assists the user throughout its procedures by performing information management tasks, executing external support tasks, organizing analysis modules and executing these modules in the user defined order while maintaining processing continuity.
Endres, Ned M.↗
Fabrication and Performance Evaluation of Double-Sided Copper Nanowire Arrays as Thermal and Electrical Interfacial Layers
Reducing contact interface thermal and electrical resistances is in great demand across various industries, particularly in the semiconductor industry. This study introduces an approach using double-sided copper nanowire (Cu NW) arrays on copper sheets as both thermal and electrical interfacial layers, designed to effectively accommodate the topographical inconsistencies between contact surfaces. Further, experimental outcomes reveal a significant reduction in thermal contact resistance (TCR), with a value of 2.5 mm 2 K W –1 , thereby exceeding the efficiency of reported nanostructural thermal interface materials (TIMs). Additionally, when utilized as an electrical interfacial layer, these double-sided Cu NWs arrays dramatically reduced electrical contact resistance (ECR), outperforming traditional conductive grease in applications necessitating separable bonding, though showing comparable performance to costly silver-based conductive epoxies required for permanent, inseparable bonds. The promising results of the double-sided Cu NWs arrays in reducing both TCR and ECR, confirmed by finite element simulation, highlight their substantial potential in advancing TIMs and electrical interconnection applications across various sectors.
42 ENGINEERING↗
Orion Landing Simulation Eight Soil Model Comparison
LS-DYNA finite element simulations of a rigid Orion Crew Module (CM) were used to investigate the CM impact behavior on eight different soil models. Ten different landing conditions, characterized by the combination of CM vertical and horizontal velocity, hang angle, and roll angle were simulated on the eight different soils. The CM center of gravity accelerations, pitch angle, kinetic energy, and soil contact forces were the outputs of interest. The simulation results are presented, with comparisons of the CM behavior on the different soils. The soils analyzed in this study can be roughly categorized as soft, medium, or hard, according to the CM accelerations that occur when landing on them. The soft group is comprised of the Carson Sink Wet soil and the Kennedy Space Center (KSC) Low Density Dry Sand. The medium group includes Carson Sink Dry, the KSC High Density In-Situ Moisture Sand and High Density Flooded Sand, and Cuddeback B. The hard soils are Cuddeback A and the Gantry Unwashed Sand. The softer soils were found to produce lower peak accelerations, have more stable pitch behavior, and to be less sensitive to the landing conditions. This investigation found that the Cuddeback A soil produced the highest peak accelerations and worst stability conditions, and that the best landing performance was achieved on the KSC Low Density Dry Sand.
Mark, Stephen D.↗
Performance of a MQXF Nb 3 Sn Quadrupole Magnet Under Different Stress Level
In a dipole or in a quadrupole accelerator magnet, the displacement of the coil turns induced by the electromagnetic forces can cause quenches limiting the magnet performance. For this reason, an azimuthal preload is applied to avoid azimuthal movements of the coil up to the required operational current. However, several tests showed that accelerator magnets can operate with a partial preload, i.e. that coil unloading during the ramp does not prevent reaching higher currents. This issue is particularly relevant for Nb 3 Sn magnets, where the loads applied to the Nb3Sn filaments can reach the degradation limits of critical current. In order to investigate the impact of coil preload on the quench performance, the MQXFS6 short model quadrupole for the High Luminosity Upgrade was tested under an azimuthal preload at 80% of the short sample current, reaching 93% of short sample current at 1.9 K. The preload was then released to 60%, still showing ability to operate in the range of 80-85% of short sample current as required by HL-LHC project. With this lower preload, the ability of going above 90% of short sample was lost, and a significant training appeared above 85%. When the preload was restored to the original 80% value, the magnet reached with few quenches 95% of short sample (13.4 T peak field). Magnetic measurements confirm the larger movement of the coil in the case with lower preload, and agree with finite element simulations.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Thermodynamic theory of crystal plasticity: Formulation and application to polycrystal fcc copper
We present a thermodynamic description of crystal plasticity. Our formulation is based on the Langer-Bouchbinder-Lookman thermodynamic dislocation theory (TDT), which asserts the fundamental importance of an effective temperature that describes the state of configurational disorder and therefore the dislocation density of the crystalline material. We extend the TDT description from isotropic plasticity to crystal plasticity with many slip systems. Finite-element simulations show favourable comparison with experiments on polycrystal fcc copper under uniaxial compression, tension, and simple shear. Here, the thermodynamic theory of crystal plasticity thus provides a thermodynamically consistent and physically rigorous description of dislocation motion in crystals. We also discuss new insights about the interaction of dislocations belonging to different slip systems.
36 MATERIALS SCIENCE↗
A high-frequency, low-power resonant radio-frequency neutron spin flipper for high-resolution spectroscopy
Here, we present a resonant-mode, transverse-field, radio-frequency (rf) neutron spin flipper design that uses high-temperature superconducting films to ensure sharp transitions between uniform magnetic field regions. Resonant mode allows for low-power, high-frequency operation but requires strict homogeneity of the magnetic fields inside the device. This design was found to efficiently flip neutrons at 96.6 ± 0.6% at an effective frequency of 4 MHz in bootstrap configuration with a beam size of 2.4 × 2.5 cm 2 and a wavelength of 0.4 nm. The high frequency and efficiency enable this device to perform high-resolution neutron spectroscopy with comparable performance with currently implemented rf flipper designs. The limitation of the maximum frequency was found due to the field homogeneity of the device. We numerically analyze the maximum possible efficiency of this design using a Bloch solver simulation with magnetic fields generated from finite-element simulations. We also discuss future improvements of the efficiency and frequency to the design based on the experimental and simulation results.
47 OTHER INSTRUMENTATION↗