Residual deformation and failure are two critical issues in powder bed fusion (PBF) additive manufacturing (AM) of metal products. Residual deformation caused by the non-uniform residual stress distribution dramatically affects the quality of AM product and can result in catastrophic failure in operation. Therefore, the development of an effective numerical approach to predict residual deformation and failure characteristics of AM product is always a major concern in industrial applications.

In this paper, a numerical approach in predicting residual distortion, stress and failure in AM products is presented. The conventional inherent strain method used in welding process is modified to consider the specific characteristic of AM process, such as the influences of reheating and scanning pattern. This approach consists of three simulation steps including a detailed process simulation in small-scale, a onetime static mechanical finite element analysis in part-scale, and a material failure analysis. First, the inherent strains are calculated from a thermo-mechanical process simulation in small-scale, which considers AM process parameters, such as laser power, scanning speed and path. The physical state in deposited materials including powder, liquid and solid states are taken into account in the simulation by specifying the solidus and liquidus temperature and corresponding material properties. Then the inherent strains are applied layer by layer to the part-scale simulation, where the residual distortion and stress can be predicted efficiently. Finally, a Lagrange particle method is utilized to study the failure characteristics of AM products. Numerical examples are studied to investigate the effectiveness and applicability of present approach.

In this paper, we develop the isogeometric analysis of the dual boundary element method (IGA-DBEM) to solve the potential problem with a degenerate boundary. The non-uniform rational B-Spline (NURBS) based functions are employed to interpolate the geometry and physical function. To deal with the rank-deficiency problem due to the degenerate boundary, the hypersingular integral equation is introduced to promote the full rank for the influence matrix in the dual BEM. Finally, three numerical examples are given to verify the accuracy of our proposed method. Both circular and square domains subjected to the Dirichlet boundary condition are considered. The engineering problem containing a degenerate boundary is considered, e.g., a seepage flow problem with a sheet pile. Numerical results of the IGA-DBEM agree well with these of the exact solution and the original dual boundary element method.

Three types of polymer including polyurethane, polyethylene, and polysulfone were used as filler inside composite tubes to evaluate their effects on the crashworthiness. The composite tube consisting of carbon fiber fabric and polyurethane was fabricated by resin transfer molding and subjected to impact loading. In addition, the finite element analysis with progressive failure and delamination was used to simulate the crushing behavior of the polymer-filled composite tube. From the comparison between experiment and simulation, the finite element analysis is reliable, could reasonably describe the crushing behavior of the polymer-filled tube, and has nice prediction on the crashworthiness performance. From both the experiment and simulation results, the polyethylene-filled composite tube has clearly higher specific absorbed energy than the hollow composite tube, and polyethylene could be considered as an effective filler. However, the other two types of polymer filler have no clear effect.

There has been considerable interest in stratospheric airships as a cost-effective alternative to earth orbit satellites for sightseeing, aerial photography, communication and carrying weapons, etc. Many countries have plans to develop the airship owing to its greatly expected usage. The suspended curtain plays a vital role in force transmission in stratospheric airships but lacks attention. In this paper, the relationship between the optimal shape of suspended curtain and load conditions was studied through CAE Abaqus and Isight. Firstly, by using secondary development function of Abaqus, parametric FEA models of suspended curtains and envelopes have been established, several parameters were used to describe the shape of suspended curtains. Secondly, parameters of the suspended curtain shape were optimized under different loading conditions by means of the genetic algorithm. Lastly, through the analysis of the results, some conclusions are summarized: The relationship between n1(n2) and nb was found to be linear when the suspended curtain is subjected to vertical load. The stress transfer law of suspended curtain and inflatable membrane structure under the inclined load were also obtained, which are valuable for the structural engineering design of stratospheric airships..

Due to the high brittleness, cracks, holes, and other defects that are easily generated in quasi-crystal structures can affect safe applications in serious cases. For guided wave non-destructive testing, the propagation of Lamb and SH waves in functionally graded one-dimensional hexagonal quasi-crystal plates are investigated. Governing equations of wave motion in the context of Bak’s model are deduced and solved by the Legendre orthogonal polynomial method. Dispersion curves, phonon and phason displacement, and stress distributions are illustrated. The convergence of the present method applied to functionally graded quasi-crystal plates is verified. Moreover, the influences of the phonon-phason coupling effect and graded fields on wave characteristics are analyzed. Some new results are obtained: angular frequencies of phason modes always decrease as phonon-phason coupling coefficients, Ri, increase; and phonon and phason displacements of Lamb and SH waves at high frequencies are mainly distributed in the region that contains more quasi-crystal material with a smaller elasticity modulus and less rigidity. The obtained results establish the theoretical foundation of guided wave non-destructive testing for functionally graded quasi-crystal plates.

Thermosonic wire bonding is a common fabrication process for connecting devices in electronic packaging. However, when the free air ball (FAB) is compressed onto the I/O pad of the chip during bonding procedure, chip cracking may occur if the contact pressure is too large. This study proposes an effective simulation technique that can predict the wire ball geometry after bonding in an accurate range. The contact force obtained in the simulation can be used for possible die cracking behavior evaluation. The simulation in this study used the explicit time integration scheme to deal with the time marching problem, and the second-order precision arbitrary Lagrangian-Eulerian (ALE) algorithm was used to deal with the large deformation of the wire ball during the bonding process. In addition, the equilibrium smoothing algorithm in LS-DYNA can make the contact behavior and geometry of the bonding wire almost the same as the experiment, which can also significantly reduce the distortion of the mesh geometry after remeshing.

Precise bone cut is fundamental in total knee arthroplasty. However, notching of anterior femoral is not uncommon in clinical practice. Reviewing the article, notching and its complication may reach up to 30% and 2.5%, and there is scanty study of notching on the femoral strength. We therefore conduct the finite element analysis to elucidate the effect of notching on femoral mechanical strength. The computerized tomography images were used as the basis to develop the knee model, which was assumed mainly to consist of cortical and cancellous bones. For the implant joint, Zimmer data was considered partly as the basis to develop the model. This study investigated the femoral improper cut effect on the surgery with a static standing condition. The results show that the anterior femoral cut should be undercut 2 mm to overcut 1 mm during the surgery, in order to prevent bone materials from yielding. The exposure of the cancellous bone may cause bone materials to yield when the femur overcut was 2 mm; the cancellous bone may load too much and result in a fracture when the undercut was 3 mm. The effect of undercut, which was rarely discussed, was particularly addressed in our study. Precise femoral cut is crucial for the longevity of total knee arthroplasty.

A non-classical analytical model for vibration analysis of thin isotropic and FGM plate containing multiple part-through cracks (star shaped) of arbitrary orientation is proposed. A plate containing four concentric cracks of arbitrary orientation in the form of continuous line is considered for analysis. The proposed governing equation is derived based on classical plate theory and modified couple stress theory. Line spring model is modified to accommodate all the crack terms. The application of Berger’s formulation introduces nonlinearities in the governing equation and then the Galerkin’s method is applied for solving final governing equation. Results for fundamental frequencies for different values of crack length, crack orientation, gradient index and material length scale parameters are presented for two different boundary conditions. Furthermore, to study the phenomenon of bending hardening/softening in a cracked plate, the frequency response curves are plotted for the parameters stated above. Based on the outcomes of this study, it can be concluded that stiffness of the plate is severely affected by the presence of multiple cracks and the stiffness goes on decreasing with increase in number of cracks thereby affecting the fundamental frequency.

The present study deploys a continuum mechanics approach called peridynamics to investigate the damage behaviour of a 2D microstructure, which was taken from a plasma sprayed ceramic coating used in solid oxide fuel cell (SOFC) sealing systems. At the beginning, two benchmark cases, namely, plate with a hole as well as plate with a single edge notch, are considered. The results are compared to an analytical solution and a very good agreement is obtained. Based on these findings, a microstructural model from a plasma sprayed ceramic coating of SOFC sealing systems is investigated. These micromechanical simulations show that structural defects influence the crack initiation as well as the crack propagation during interconnecting the defects. Typical crack mechanisms, such as crack deflection, crack shielding or multiple cracking, are observed. Additionally, an anisotropy of the effective mechanical properties is observed in this heterogeneous material, which is well known for plasma sprayed materials.

To understand the lubrication-dominated permeation through a membrane, numerical simulations of permeation through a moving corrugated permeable membrane is carried out with a fully validated numerical method. Through comparisons between the numerical results and the results of an asymptotic analysis of permeate flux (under an infinitesimal permeability condition) using Reynolds lubrication equation, the effect of permeation on lubrication and its inverse effect (i.e., the dependence of permeation on lubrication) are discussed. The linear and non-linear dependences of the relaxation of the lubrication pressure due to membrane permeation are identified. The effect of the tangential component of the permeate flux is evaluated by a linear analysis, and the limitation of Reynolds-type lubrication is discussed.

The stress field induced by an edge dislocation or a point force located near a coated triangle-like hole in an infinite plate is provided in this paper. Based on the method of analytical continuation and the technique of conformal mapping in conjunction with the alternation technique, a series solution for the displacement and stresses in the coating layer and the matrix is obtained analytically. Examples for the interaction between an edge dislocation and a coated triangle-like hole for various material constant combinations, coating thicknesses and shape factors are discussed. The analysis discovers that the so-called trapping mechanism of dislocations is more likely to exist near a coated triangle-like hole. The result shows that the dislocation will first be repelled by the coating layer and then attracted by a hole when the coating layer is slightly stiffer than the matrix. However, when the coating layer is sufficiently thin, the dislocation will always be attracted by a hole even the coating layer is stiffer than the matrix.

In this paper, the Rayleigh wave propagation is investigated in rotating half-space of incompressible monoclinic elastic materials which are subjected to the impedance boundary conditions. In particular, the explicit secular equation of the Rayleigh wave is obtained. The main objective of this paper is to illustrate the dependence of dimensionless speed of Rayleigh wave on rotation, anisotropy and impedance parameters. An algorithm in MATLAB software is developed to solve the secular equation of Rayleigh wave. The speed of Rayleigh wave is plotted against rotation, anisotropy and impedance parameters.

In this study, a spherical indenter mounted on an atomic force microscope (AFM) was used to compress a Nannochloropsis oculata (N. oculata) cell on a poly-l-lysine coated slide. A mathematical model of the cell, which was derived by considering a fluid-filled spherical shell with axisymmetric compression between a sphere and an infinite flat plate, is proposed. In the construction of this mathematical model, the spherical shell was assumed to be a homogenous, isotropic, and elastic material. Thin-film theory was applicable to the spherical shell because the thickness of the shell was nearly negligible compared with its diameter. The governing equations of the contact and noncontact regions were converted from a boundary condition problem to an initial value problem. Then, the fourth-order Runge–Kutta method was applied to solve the transformed governing equations. The force curve obtained from the compression experiment was compared with the theoretical results derived from the proposed model. Furthermore, the numerical solution of the proposed model was verified to be consistent with the experimental data. The mechanical properties of cell walls were confirmed by applying the least square error method. Subsequently, the contact radius, inner pressure and tension distribution of the cell wall could be determined using the proposed model. The models proposed in other studies are suitable for analyzing the compression characteristics of cells whose size is of the order of tens of micrometers and millimeters. By contrast, the model proposed in this study can analyze the compression characteristics of N. oculata, which is only a few micrometers in diameter. Furthermore, a force curve that accurately describes the deformation behavior of N. oculata under strain levels of 25% was established.

Silicon (Si)-based materials are sought in different engineering applications including Civil, Mechanical, Chemical, Materials, Energy and Minerals engineering. Silicon and Silicon dioxide are processed extensively in the industries in granular form, for example to develop durable concrete, shock and fracture resistant materials, biological, optical, mechanical and electronic devices which offer significant advantages over existing technologies. Here we focus on the constitutive behaviour of Si-based granular materials under mechanical shearing. In the recent times, it is widely recognised in the literature that the microscopic origin of shear strength in granular assemblies are associated with their ability to establish anisotropic networks (fabrics) comprising strong-force transmitting inter-particle contacts under shear loading. Strong contacts pertain to the relatively small number of contacts carrying greater than the average normal contact force. However, information on how such fabrics evolve in Si-based assemblies under mechanical loading, and their link to bulk shear strength of such assemblies are scarce in the literature. Using discrete element method (DEM), here we present results on how Si-based granular assemblies develop shear strength and their internal fabric structures under bi-axial quasi-static compression loading. Based on the analysis, a simple constitutive relation is presented for the bulk shear strength of the Si-based assemblies relating with their internal fabric anisotropy of the heavily loaded contacts. These findings could help to develop structure-processing property relations of Si-based materials in future, which originate at the microscale.

Digital manufacturing was employed to 3D print continuous Carbon, Glass and Kevlar fibre reinforced composites in Unidirectional (UD) [0°], Off-axis ±45° and Cross-ply [0°/90°] layup sequence. These 3D printed composites were subjected to quasi-static, in-plane tension and out-of-plane (compression and shear) loading. The tensile strength of 3D printed Carbon, Glass and Kevlar UD laminates was significantly lower than that of 3D printing filaments used to manufacture them. The type of fibre (brittle/ductile) reinforcement was found to be governing the shear yield strength of 3D printed composites despite having the same Nylon matrix in all the composites. Out-of-plane compressive strength of the 3D printed Carbon and Glass fibre reinforced composites was independent of specimen size. Contrary to that, Kevlar fibre composites showed a pronounced size effect upon their out-of-plane compressive strength. A combination of X-ray tomography and pressure film measurements revealed that the fibres in 3D printed composites failed by ‘indirect tension’ mechanism which governed their out-of-plane compressive strength. To gain further insights on the experimental observations, Finite Element (FE) simulations were carried out using a pressure-dependent crystal plasticity framework, in conjunction with an analytical model based on shear-lag approach. Both FE and analytical model accurately predicted the out-of-plane compressive strength of all (Carbon, Glass and Kevlar fibre reinforced) 3D printed composites.

The quest for drag reduction is driven by environmental concerns, in general, and the need to reduce fuel consumption in transport applications, in particular. Turbulent friction is especially important in civil aviation, accounting for over 50% of the total drag in cruise. In this context, spatially and/or temporally varying in-plane wall motion, while undoubtedly difficult to implement in practice, has attracted major interest, because of the large drag-reduction margins it yields. It is also a forcing method that is of fundamental interest, as it provokes intriguing interactions between the spanwise Stokes layer induced by the wall motion and the near-wall turbulence-regeneration mechanisms. This article provides a relatively brief, ‘entry-level’, review of research in this area, principally over the past two decades. While far from being exhaustive, the review conveys a reasonably detailed picture of some major physical issues as well as of the outcome of the most important computational and experimental studies. Particular emphasis is placed on the question of how results obtained in idealised laboratory conditions and by simulation at relatively low Reynolds-number values pertain to high values typical of high-speed transport.

This paper focus on the mechanical and martensitic transformation behaviors of axially functionally graded shape memory alloy (AFG SMA) beams. It is taken into consideration that material properties, such as austenitic elastic modulus, martensitic elastic modulus, critical transformation stresses and maximum transformation strain vary continuously along the longitudinal direction. According to the simplified linear SMA constitutive equations and Bernoulli-Euler beam theory, the formulations of stress, strain, martensitic volume fraction and governing equations of the deflection, height and length of transformed layers are derived. Employing the Galerkin’s weighted residual method, the governing differential equation of the deflection is solved. As an example, the bending behaviors of an AFG SMA cantilever beam subjected to an end concentrated load are numerically analyzed using the developed model. Results show that the mechanical and martensitic transformation behaviors of the AFG SMA beam are complex after the martensitic transformation of SMA occurs. The influences of FG parameter on the mechanical behaviors and geometrical shape of transformed regions are obvious, and should be considered in the design and analysis of AFG SMA beams in the related regions.

In the present study, we use direct numerical simulation to investigate the density-driven convection in a two-dimensional anisotropic heterogeneous porous media associated with significant laminated formation. At first, the heterogeneous porous media are randomly generated to represent laminated structure, in which the horizontal correlation length of permeability field is much longer than the vertical counterpart. Then, a highly accurate pseudo-spectral method and compact finite difference scheme with higher order of accuracy are employed to numerically reproduce the convection flow in the laminated porous media. The results show that the laminated structures restrict interactions among the downward plumes of heavier fluid. The plumes tend to descend more straightly in a laminated porous medium associated with a slower growth rate. As a result, the laminated distribution of permeability is considered having an inhibiting effect on the convection flow.

The elastoplastic behavior of a Functionally Graded Material (FGM) simply supported beam consisting of elastic material A and elastoplastic material B under uniformly distributed load is investigated. A power function is used to describe the volume fractions of the constituent materials, and the average stress of the FGM beam is obtained by using the averaging method. This method can avoid the assumption of the varying properties of the whole material, and can consider the different Possion’s ratios of the different constituent materials. What’s more, only the elastoplastic material B in the FGM beam will yield, and the yield function is determined by the stress of material B only, rather than the average stress of the whole material. The method used in this work is more closer to the real material than the method by assuming the variation of the whole properties of FGM. The theoretical results show a good agreement with the finite element results, which indicates that the method provided in this work is valid. With this method, the variation of the elastic and plastic areas, the stress distribution on the cross section, variation of the curvature and neutral layer, and the residual stress distribution of the FGM beam are discussed through numerical results. This work can provide a new way for the design and in-depth investigation of FGM material.

Investigation of SH wave scattering by inclusions in bi-material half space is an important issue in engineering. The purpose of this work is to study the dynamic response of a semi-circle inclusion embedded in bi-material half space surface by SH wave. Graf's addition theorem, Green function method and region-matching technique are used to determine the displacement fields in the bi-material half space and the inclusion. The distributions of dynamic stress concentration factor (DSCF) around the semi-circle inclusion are depicted graphically considering different material parameters. The results show that the frequency and the incidence angle of SH wave, the rigidities of the inclusion and bi-material half space, and the distance from the inclusion to the interface have a great effect on the distribution of DSCF around the inclusion.