Papers by Keyword: FEA

Abstract: Transverse (charge) welds form during billet transitions in aluminium extrusion when incoming material progressively replaces residual metal inside the die, defining the length of extrudate that must be scrapped. This study aimed to quantify charge weld evolution under industrially relevant conditions that are often underestimated in scrap length assessment, including multi-cavity flow imbalance, non-symmetric multi-profile placement, and billet-to-billet thermal stabilisation effects. Three case studies were analysed using finite element simulation in QForm UK: (i) the International Extrusion Benchmark 2023 multicavity die producing three hollow tubes with intentionally varied port and bearing designs, (ii) an industrial two-profile die with translated (non-mirrored) profile positioning to avoid post-extrusion rotation, and (iii) a complex industrial profile extruded over multiple consecutive billets. The benchmark study demonstrated strong agreement between simulation and experimental charge weld evolution for two profiles, supporting the reliability of the predicted cavity-dependent differences driven by port volume. In the translated two-profile configuration, the charge weld cut length required for full purity increased from 1674 mm to 1940 mm (+16.0%), and by +15.9% under the 95% industrial criterion (1458.1 mm vs 1690.7 mm). Billet-to-billet variability was substantial, with charge weld length increasing by +70.1% from the first to the fifth billet (2819.0 mm to 4791.7 mm), before stabilising. Overall, the results show that charge weld length is governed by residence-time differences through ports and flow channels, requiring profile-specific assessment and consideration of process stabilisation. In this context, FE simulation provides an effective means to localise the mixed zone and to support die optimisation strategies aimed at reducing scrap.

Abstract: This study presents a report on the energy content enhancement of biomass derived from palm kernel shells (PKS) by varying the sample sizes using a developed hammer mill machine. A hammer mill was designed, simulated, and constructed to efficiently mill palm kernel shells into various particle sizes. Finite Element Analysis (FEA) was performed on the hammer mill’s frame and shaft, ensuring the structural integrity of the machine under operational loads. The machine’s rotor, crushing chamber, hammers, sieves, and prime mover were strategically engineered to achieve precise size reduction while maintaining operational efficiency and durability. The energy content of the selected biomass was evaluated for the control PKS sample and the milled PKS sample of two different particle sizes (0.4 and 0.6 mm). The main objective of this research was to examine palm kernel shells' energy potential by analysing the impact of particle size reduction on their energy content. To evaluate the energy characteristics of the processed biomass (grain size reduction), proximate and ultimate analyses were conducted on each particle size fraction, assessing parameters such as moisture content, volatile matter, ash content, fixed carbon, elemental composition (carbon, hydrogen, oxygen, nitrogen, and sulfur), and calorific value. The results revealed a direct correlation between particle size and energy content, with finer particles exhibiting improved combustion properties due to increased surface area and enhanced reactivity. It is found that higher carbon content of the milled PKS samples (54.5% at 0.4 mm and 48.37% at 0.6 mm), representing 49.4% and 43.04% enhancement, respectively, over the control PKS sample before the milling process was achieved in this study. The results of which yield a 3.36% energy content increment in terms of particle size variation from 0.4 to 0.6 mm, highlighting enhanced energy efficiency in this work. The attained reduced nitrogen and sulfur content of the milled samples in this work contributes to lower greenhouse gas emissions, making them a more environmentally sustainable biofuel option. These findings elucidate the potential of particle size optimization as an effective approach for improving the energy content of PKS, thereby enhancing its suitability as a clean and efficient bioenergy source.

Abstract: Atomic Weopons Establishment (AWE) is tasked with substantiating the performance of numerous systems in diverse environments. Often this involves both experimental trials and numerical analysis undertaken in an integrated manner. One area in which this approach has been applied is the assessment of structural response to blast loading. Experimental testing is undertaken using blast tunnels/tubes to generate surrogate environments and obtain appropriate load profiles. AWE’s Air Blast Tunnel (ABT) – a unique facility for generating large-scale long duration blast waves – is commonly employed for this purpose. Modelling activities, including finite element analysis (FEA), hydrocode analysis and engineering calculations, are performed in conjunction with the trials to optimise their output. Data collected during the tests is subsequently exploited to facilitate model validation. Validated models are then used to study the true environments of interest. To complement the ABT and provide a facility in which new and novel test methods and technologies can be explored, the ‘Mini Air Blast Tunnel’ (MABT) was recently designed and constructed by AWE. One of the first applications of this facility was to support exploration of methods to engineer blast profiles and scale to larger tunnels; an area of ongoing interest. 18 shots were fired with various configurations of frangible section and/or tunnel blockage to study their effect on the blast profiles obtained. This study was accompanied by complementary analysis employing coupled Fluid-Structure Interaction (FSI). Pressure data recorded during the experimental trial were used to validate the model prior to it being exploited to consider further configurations that were not tested. The analysis revealed the influence of the thickness and strength of the frangible section on pressure-time histories within it, as well as the impact of blockage on increasing load on the test item in addition to the internal radial load applied to the tunnel structure. An overview of the trial and modelling activities will be provided whilst highlighting key similarities and differences between model and test results. The challenges and limitations encountered in the study and its potential future direction will also be discussed.

Abstract: As a result of the high strength-to-weight ratio, the automobile industry is becoming increasingly interested in replacing steel springs with composite leaf springs. The task at hand is to swap out some steel springs for alloy springs. The car's suspension impacts how comfortable it is to drive and how much damage it sustains. The leaf spring group's primary role is to support the suspension element's vertical load. The contact between the blades makes adjusting the crossbow's action more difficult. The goal of this article is to replace steel multi-disc springs with single joint springs that have a higher load carrying capacity and are more stiff. This alloy offers a greater strength-to-weight ratio and a more elastic corrosion energy storage capacity than steel. The crossbow's weight can be lowered without sacrificing the crossbow's load capacity or stiffness. The stress and displacement are controlled by the barrier design.

Abstract: The research investigates the application of static structural finite element analyses in studying spiral bevel teeth gear of Polski fiat with four tooth angles at 25, 30, 35, 40 degrees. The researchers simulated 16 times using Ansys, investigating all the load cases. These included elements such as deformations, normal stress, equivalent stress at the tooth contacts. Findings provide guidance on gear updating and improvement in gearbox gearing response, which enhance subsequent generation mechanical systems.

Abstract: This work addresses the challenges associated with the development of short neutral sections (SNS) for overhead lines of high-speed moving trains. A crucial function of a short neutral section is to provide electrical isolation between the different phases of AC traction. These sections are typically located in proximity to the traction substation and sectioning posts. The current SNS design presents several issues, including pantograph arcing, wear and tear of the overhead line system, and the need for manual rotation during periodic maintenance. To address these challenges TRIZ is used, a problem-solving methodology that leverages inventive principles to generate innovative solutions. The work outlines the use of several TRIZ tools and techniques, including the Interaction Matrix, Functional Analysis, Function-Body Diagram (FBD), Trimming, and the Contradiction Matrix [1]. With the application of these tools, the author presents several potential solutions for improving the SNS design to eliminate periodic maintenance and services. One proposed solution involves the use of a segmented overhead line system with an insulating cylinder-shaped discrete insulator to ensure smooth contact of the pantograph. Another solution involves the use of a twisted strip-based insulator to replace linear motion with rotating movement, eliminating the need for manual rotation. The work emphasizes the importance of considering various factors, such as design, material, wear rate, maintenance, and creepage distance, when evaluating the feasibility of these solutions. By leveraging TRIZ to generate innovative solutions, the author demonstrates the potential of this methodology to drive innovation and overcome complex challenges in the development of short neutral sections for high-speed rails.

Abstract: A Blowout Preventer (BOP) serves as a safety valve in the drilling process in the oil and gas industry. It will be closed if an influx of formation fluids occurs and threatens the rig. A Ram BOP is one type of widely used BOP. It is composed of two ram blades, which will move toward each other to shear the drilling pipe and to close the valve. To ensure the shearing process is completed on the rig, lab tests are often run to evaluate the BOP’s capability and the required shearing pressure. Over the last decade, Finite element analysis (FEA) based simulation method has been set up to predict the shearing process. The simulation method still requires pipe damage parameters and requires lab test. This paper presents a test-free simulation method enabled by analyzing the ram BOP pipe shearing data, which significantly reduces the lead time and test costs.

Abstract: In progressive die stamping processes, maintenance activities caused by tool damage, and wear represent economic losses for companies. An effective predictive maintenance strategy can only be implemented if maintenance data coming from the operations are correlated to specific process-related information. As a part of a more general data-based predictive maintenance strategy, the main causes of tool damage and wear in a progressive die stamping factory that produces automotive metal washers have been identified by means of FEA simulations. In this study, the progressive die stamping of a dented conical washer is simulated with Transvalor FORGE FEA software by implementing the process parameters used in a real case. In this study, two indicators called FEA_wear and FEA_damage are proposed for prediction of die wear and damage for tools with high risk of failure. For validating the accuracy of the FEA simulations, dimension and geometry comparisons are performed between FEA and real washer, and then real and FEA maximum press force comparison is performed. In the end, FEA simulations demonstrated their accuracy in predicting the stamping force of the press and the final part quality, and proposed FEA damage and wear indicators accurately predicted the most critical tools and stations, as confirmed by the real maintenance data. Finally, the simulations also correctly detected potential damage zones of the tools.

Abstract: A pin-connected joint, which was intended to accommodate a certain in-plane rotation and resist the shear forces, was introduced in this paper. Pinned-connections were applied on Truss-Column joints to support the heavy-loaded floors and roofs in a long-span steel structure. The Pinned-connection was designed in accordance with European code, and compared with other standards such as America standard and Australia standard. To better understand the behavior of materials and structure of this pin-connection structural system, four specimens, including two full-scale pin-connections and two truss connections, were tested to investigate the performance under both monotonic and cyclic loads. The load–displacement curves, hysteretic curve and ultimate loads were obtained, and the failure mode, capacity and ductility were discussed. The experimental and numerical results indicated that the pin-connection behaved good ductility, load transfer ability and capacity.

Abstract: One of the laminated bamboo production processes uses a bamboo planer machine. The use of this technology creates great opportunities for improving the quality of the bamboo processing process. Existing equipment still requires improvements to the power transfer mechanism and system, which affects the frame's shape. Therefore it was necessary to design and retest the frame design so that the machine can produce good shavings. The frame design comprises 50 mm × 50 mm × 5 mm angled steel with ASTM A36 material standardization. The testing method was finite element analysis (FEA) using SolidWorks. The frame was tested using static loading simulation to take mass, maximum stress, deflection, and safety factors. From the simulation, the safety factors value was 6,513. It was too high compared with the predetermined criteria, so the thickness of the frame was changed to 4 mm. The optimization increases material efficiency by 18,227% resulting in reduced frame mass to 76,576 kg. The result of the safety factor becomes 5.930. Keywords: FEA; Frame; Bamboo; Optimization; Strength Analysis; Planer Machine