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  A Computational Approach for the Estimation of Elastic Behavior of Metal Matrix Composites

  Emmanuel Michalakis

  Composite materials are being widely used in many industries for their properties and efficiency. The current work presents a computational approach that can estimate the elastic behavior of metal composites and porous materials using finite element models of representative volume elements (RVEs) which have been used to test and design particulate composite materials. The required size of the RVE for the determination of elastic properties, the effects of the elastic modulus fraction Einc/Emat on the homogenized elasticity and the convergence of the homogenized properties E11, E22 and E33 with the size of the RVE is explored.

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  A Computational Approach for the Estimation of Elastic Behavior of Metal Matrix Composites

  Emmanuel Michalakis

  Composite materials are being widely used in many industries for their properties and efficiency. The current work presents a computational approach that can estimate the elastic behavior of metal composites and porous materials using finite element models of representative volume elements (RVEs) which have been used to test and design particulate composite materials. The required size of the RVE for the determination of elastic properties, the effects of the elastic modulus fraction Einc/Emat on the homogenized elasticity and the convergence of the homogenized properties E11, E22 and E33 with the size of the RVE is explored.

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  Analysis of a Baja SAE Chassis from a Static Drop

  Nathaniel Williams, Austin Chaffin, Julie Louque, and Joseph Tillery

  The MSU Baja SAE team designed an all-terrain sport vehicle for national competition. This vehicle was made with a fully welded, tubular 4130 steel frame chassis, which takes the abuse from rollovers, vehicle impacts, and rough terrain. A team member of the Baja team requested the project group to perform a Finite Element Analysis on the chassis during a vertical drop. This scenario tested the chassis’ performance and long-term endurance during suspension loading from four to five feet drop in the air. The initial simulation used a simple wireframe model of the chassis to test the assumptions, boundary conditions, and loading conditions during axial loading. After gaining understanding of the model’s reaction during the simulation, the team enhanced the model into a solid body to run a secondary analysis and mesh refinement. The results of the second analysis were used to optimize the cost and design of the chassis within the SAE requirements and constraints.

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  Analysis of Seismic Effects on Bridge Substructures with Steel Pipe Piles Using the Finite Element Method

  Alex Hawkins

  The purpose of this paper is to research and analyze the effects of seismic forces on bridge substructure support caps with steel pipe piles using the finite element method. Trestle bents, or pile supports, act as an intermediary between the girder loads and the piles that carry those loads. These piles do not experience bending moments from the superstructure like a frame bent would, but they can experience potential moments due to seismic forces. A single support is modeled in finite element software with response spectrum values input into the software to run an analysis. Using the AASHTO Guide Specification for LRFD Seismic Bridge Design as a guide will determine the overall resistance of the structure when subjected to seismic forces. The analysis will hope to demonstrate the stresses and displacements the pile experiences as well as its effects on the superstructure it is supporting. Displacement demands and capacities serves as the seismic design basis for the structure. If the demand becomes greater than the capacity, then the structure fails.

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  Bulge Error Reduction

  William Thomas Downs, Turner Dauma, and Sterling McGee

  Wire electrical discharge machine cutting (EDM) offers high precision fabrication methods unseen among other cutting techniques. It involves submerging the subject to be cut in dielectric liquid and using a highly charged carbide wire to remove material across a very small cutting face. Similar to other subtractive manufacturing methods, there is an assumed level of error and imprecision. The most common within the scope of wire EDM cutting is referred to as “bulge error”. This is largely attributed to the relaxation and dispersion of internal stresses within the cut object relaxing and deforming the cutting geometry, exasperated with time and/or length. From previous research, the contour method is used to map and identify residual stresses within a machined specimen across an area of observation. Derived by Hooke’s Law, our analysis serves to map the displacement about our cut faces similar to those in a contour method stress map. Likewise, adequate fixturing of a specimen is a foundational step in the manufacturing process with respect to the desired manufacturing process to reduce machining inaccuracy. The research outlined below serves to justify a fixturing solution of test objects cut by wire EDM. The contour method is used as an expression of the bulge error across these simulations to validate and corroborate the inaccuracy induced amongst the fixture and wire EDM cuts for laboratory use.

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  Bulge Error Reduction Analysis in Wire EDM Cutting Scenario

  Will Downs and Sterling McGee

  Wire electrical discharge machine cutting (EDM) offers a higher degree of precision compared to other fabrication methods. It involves submerging the subject to be cut in dielectric liquid and using a highly charged carbide wire to remove material across a very small cutting face. Similar to other subtractive manufacturing methods, there is an assumed level of error and imprecision. The most common within the scope of wire EDM cutting is referred to as “bulge error”. This asymmetrical error is largely attributed to the relaxation and dispersion of residual stresses within the cut object relaxing and deforming along the cutting geometry, exasperated with time and length. The contour method is used to map and identify residual stresses within a machined specimen across a plane of observation. Based on Hooke's Law, these stresses can be mapped by evaluating the displacement from the cut plane and specified material properties. The asymmetric nature of bulge error introduces bias within contour mapping analyses by displacing the contour planes beyond the calculable displacement caused by residual stress. Furthermore, adequate fixturing of a specimen is a foundational step in the fabrication process for desirable production processes and reduced machining inaccuracy. This research serves to justify a fixturing solution of test objects cut by wire EDM. A finite element model emulates residual stresses and the wire cutting process to derive a simulated strain. From this simulation, physical experiments can be compared using similar wire cutting scenarios, fixturing, and test specimens to validate the fixtures capability of reducing bulge error.

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  Combined Blast-Fragmentation

  Greg Gallagher, Chase Allen, and Micah Nichols

  A finite element analysis (FEA) of an air blast on DH-36 Steel is presented to understand the effects of the blast impacting the target. Another analysis is presented of a rigid body fragment contacting the materials mentioned to understand how the impact affects the target. A third analysis combines the blast and fragment impacting the target.

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  Comparison of Johnson-Cook and Linear Elastic-Perfectly Plastic Material Models for Ballistic Impact Case

  Logan J. Callahan, Marella Failla, and Harrison Williams

  In an effort to characterize the linear elastic-perfect plastic (J2) and Johnson-Cook (JC) Strengthening and Damage material models for an Aluminum target material being struck by a steel penetrator, finite element analysis (FEA) will be used to simulate the residual velocities from ballistic impacts, using various velocities of the penetrator. The object is to define the point at which the J2 material model is no longer accurate and therefore requires the use of the JC material models.

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  Computational Mechanics Implementation of Performance Based Testing in Massive Concrete Structures

  Gabriel Y. Riveros

  Most of the nation’s critical water resource infrastructures are near or have exceeded their design lives. Consequently, there is a huge need for the development of assessment procedures that will change the way dams are maintained and operated with the intent of extending the service life. This is crucial for ensuring the safety and security of our nation’s public services. The combination of advanced computational mechanics and performance based testing (PBT) methods can be used to investigate the existing conditions of large concrete structures.

  Performance based testing (PBT) is a new and innovative non-destructive testing technique that we are implementing to better asses critical infrastructure by the use of a Cold Gas Thruster (CGT). The CGT is an instrument that delivers a high magnitude, short duration load that produces an impulse response in the structure. PBT allows for the evaluation of critical infrastructure acquiring specific dynamic responses within the structure. The dynamic responses gathered can be used to identify specific fundamental behavior characteristics, which can then be used to monitor changes within the structure throughout the lifespan of the structures existence.

  Advanced computational mechanics will allow us to achieve a model calibration with the experimental data that in turn will provide us with the ability to change force and displacement boundary conditions to study different realistic scenarios typically encountered in massive concrete structures.

  The fundamental behavior characteristics are identified by using Shock Response Spectrum (SRS) analyses to determine the natural period of vibration of the structure. The condition of the structure can be assessed by evaluating the spectral patterns associated with each test. The natural period of vibration can be used to identify the structural stiffness and can then be compared to other PBT baseline data to determine if a change in the characteristics of the structure has occurred. The structures fundamental characteristics can be monitored and assessed by frequently testing these structures, allowing for significant changes that may put the structure at risk to be detected early.

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  Computational Mechanics Implementation of Performance Based Testing in Massive Concrete Structures

  Gabriel Y. Riveros

  Most of the nation’s critical water resource infrastructures are near or have exceeded their design lives. Consequently, there is a huge need for the development of assessment procedures that will change the way dams are maintained and operated with the intent of extending the service life. This is crucial for ensuring the safety and security of our nation’s public services. The combination of advanced computational mechanics and performance based testing (PBT) methods can be used to investigate the existing conditions of large concrete structures.

  Performance based testing (PBT) is a new and innovative non-destructive testing technique that we are implementing to better asses critical infrastructure by the use of a Cold Gas Thruster (CGT). The CGT is an instrument that delivers a high magnitude, short duration load that produces an impulse response in the structure. PBT allows for the evaluation of critical infrastructure acquiring specific dynamic responses within the structure. The dynamic responses gathered can be used to identify specific fundamental behavior characteristics, which can then be used to monitor changes within the structure throughout the lifespan of the structures existence.

  Advanced computational mechanics will allow us to achieve a model calibration with the experimental data that in turn will provide us with the ability to change force and displacement boundary conditions to study different realistic scenarios typically encountered in massive concrete structures.

  The fundamental behavior characteristics are identified by using Shock Response Spectrum (SRS) analyses to determine the natural period of vibration of the structure. The condition of the structure can be assessed by evaluating the spectral patterns associated with each test. The natural period of vibration can be used to identify the structural stiffness and can then be compared to other PBT baseline data to determine if a change in the characteristics of the structure has occurred. The structures fundamental characteristics can be monitored and assessed by frequently testing these structures, allowing for significant changes that may put the structure at risk to be detected early.

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  FEA Analysis of Hip Strength Affected by Osteoporosis

  Caitlin Cade

  Aging and the development of bone disease are inevitable life situations that can weaken a person's bones over time. The health and condition of one's bones can be affected by a variety of variables during one's life. The application of Finite Element Analysis (FEA) modeling can help researchers better understand how forces affect the bone and how to address issues that arise as a result. This research will look at the combined effects of aging and osteoporosis based on an individual's bone elastic modulus, as well as what forces may produce fracture and in which direction. The objective of this project is to provide a quick-reference chart for medical professionals to use when determining a patient's risk of fracturing a hip owing to aging and bone deterioration.

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  FEA analysis on a beam of Hexacopter Drone Frame

  aicha chahbi el alaoui and taymae ben messaoud

  Our project covers the research made, a deep analysis, the structural design, modeling, and design of a hexa copter, which has six degrees of freedom. In order to improve the drone’s dynamics and efficiency, an analysis will be conducted on one beam constituting the drone using Abacus.

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  FEA (finite element analysis) for a bead on plate weld.

  abdellah cherti and Hatim El Bakkali

  In their daily practice, professional engineers are often confronted with problems involving complex physical phenomena. Many complicated engineering problems can now be solved with computers at extraordinarily little cost in a truly short time due to the large capacity of computers, and the interest in the use of numerical methods, such as the finite element methods. Gas metal arc welding (GMAW) is an arc welding process during which the source of heat is an arc formed between a consumable metal electrode and the workpiece with an externally supplied gaseous shield of gas either inert like argon and /or helium which causes them to melt and join. Within the GMAW process a moving heat source welds the wires and deposits them on a plate, this work present how does varying the clamping conditions and interpass temperatures change the thermally induced residual stresses and distortion of the plate. The structure presented during this work is used within the navy systems to design ships and submarines, the latter, are constructed of welded plates, thus residual stresses and distortion can cause tolerance issues, stress concentrations, and premature failure under cyclic loading

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  FEA of Ballistic Impact on Lattice Structures​

  Olivia S. Russell and Gabe Morris

  Lattice structures are topologically organized porous structures composed of struts meeting at nodes. These structures are of particular interest in materials engineering because of their ability to absorb high energy while maintaining low weight. This work aims to utilize finite element analysis to simulate the ballistic impact of simple cubic lattice structures. It highlights some of the difficulties in such an analysis, such as proper damage evolution and material models, and points to recommendations to continue to improve the model.

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  Finite Element Analyses of a Test Support Structure

  Maria M. Figueroa and Joseph Brent Knight

  These documents present details of Finite Element Analyses (FEA) performed to assess the structural integrity of a given structural Test Support Structure (TSS) design. The Test Article (TA) was represented as a 500 lb. lump mass in the FEA. Typical structural pre-test analyses assess the TSS’s integrity, including the influence of the TA. They also ensure that the TSS characteristics don’t affect the test’s intent or the TA’s integrity. These efforts do not include the TA. Therefore those questions are not addressed. The TSS will be assessed in linear static stress and modal analysis.

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  Finite Element Analysis of Layer Shifting in Additive Manufacturing

  William M. Horner

  A common error for additive manufacturing processes is layer shifting. Layer shifting is an error that is usually caused by a hardware failure on the machine and shifts the position of layers in a 3D print over in the x or y-axis. An analysis was conducted to determine the additional stress concentrations that are introduced due to these defects. 3D models were generated in three phases of complexity and layer shifts were introduced at three points for each model. Layer shifts were limited to 0.1 inches for initial testing. The differences in layer shifts and layer shift orientation were examined in later-stage testing.

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  Finite Element Analysis of Motorcycle Helmet Impacts

  Morgan Calhoun and Amal Lazar

  A study of motorcycle helmet impacts using dynamic explicit Abaqus simulations.

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  Finite Element Analysis of the Brick House Ruins on Edisto Island, South Carolina When Subjected to an Earthquake Loading

  Ronald B. Smith III

  The Brick House Ruins is a historic shell of a once dignified mansion that is currently in a state of deterioration and instability. Since its location outside of Charleston, South Carolina is known for the occasional intraplate earthquake, the potential that such an event of sufficient magnitude could destroy the decrepit ruins is certainly plausible. Thus, a finite element analysis utilizing Abaqus software will simulate an earthquake loading scenario with realistic ground acceleration data to predict the expected stresses and displacements, which will reveal the areas of the structure that should be immediately shored to prevent a catastrophic collapse of the historic edifice should such a devastating earthquake occur.

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  Finite Element Modeling of Crush Tube Deformation

  Mohammed El Mehdi BENYAICH Mr and Aymane HIDARA Mr

  In this research paper, finite element methods will be implemented to analyze the crush tube deformation. It will be modeled as a classic nonlinear problem on which mesh convergence, boundary conditions, contact techniques are investigated. The finite element software ABAQUS will be used to perform FE simulation of the crushing of a tube between two flat plates under axial compressive load and the geometry used is a thin-walled rectangular cross section tube. Project deliverables for this work include the crush response of the tube with mesh sensitivity study to accurately model the buckling mode and load displacement characteristics. Mesh density and uniformity on the structure were also investigated. Other deliverables include boundary conditions versus the load applied and effects of omitting contact for buckling problem, starting with an elastic model, and then comparing it to other plasticity models in terms of strain rate and temperature dependency ABAQUS implicit versus standard solvers were both used to compare the computational time requirements, ease of convergence and contact implementation.In this research paper, finite element methods will be implemented to analyze the crush tube deformation. It will be modeled as a classic nonlinear problem on which mesh convergence, boundary conditions, contact techniques are investigated. The finite element software ABAQUS will be used to perform FE simulation of the crushing of a tube between two flat plates under axial compressive load and the geometry used is a thin-walled rectangular cross section tube. Project deliverables for this work include the crush response of the tube with mesh sensitivity study to accurately model the buckling mode and load displacement characteristics. Mesh density and uniformity on the structure were also investigated. Other deliverables include boundary conditions versus the load applied and effects of omitting contact for buckling problem, starting with an elastic model, and then comparing it to other plasticity models in terms of strain rate and temperature dependency ABAQUS implicit versus standard solvers were both used to compare the computational time requirements, ease of convergence and contact implementation. An adiabatic simulation will be added using Johnson-Cook method.

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  Finite Element Modeling of the Induction Bending Process

  Will Kirkpatrick and Jaouhar Misbah

  Induction bending is a forming process used in industry to create bends in pipes of small bending radius and large diameter. Although pipe bending is a widely used engineering process, the optimum process parameters are decided on the basis of a trial and error method by highly experienced field engineers. An issue that has been occurring with this process is cracks forming in the pipe, which makes them unusable and wastes the time and money spent on the materials. Finite Element simulations will be done to model this process, and this report will investigate the cause of these cracks. The induction bending process will be simulated within Abaqus, and the resultant stresses and strains will be provided

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  Formability of Al Sheets Using Finite Element Analysis

  Austin Freedman, Derek Newman, and Rebecca Grissom

  Develop and analyze a two-scale FE model to predict the deformation and failure behavior of high pressure die casted (HPDC) aluminum alloys, with copper particle inclusions of 6.0, 6.6, 7.3, 8.0, and 9.0 %, during a three-point wrap-bending test.

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  Leverage topology optimization to maximize structure design efficiency

  SAAD AQERROUT and Teng Li

  This paper represents topology optimization method to improve the efficiency of mechanical structure design.

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  Leverage topology optimization to maximize structure design efficiency

  Teng Li and SAAD AQERROUT

  This paper presents the topology optimization method to improve the efficiency of mechanical structure design.

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  MEDTRONIC FEA of a Spinal Rasp for Spinal Fusion Surgery

  Daniel Sieja, Harrison Fox, Caitlin Luke, and Spencer Mercier

  Using FEA to ensure that a MEDTRONIC spinal rasp will resist deformation and material failure under surgical loading conditions.

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  Mitigating the Effects of Knife Blade Misuse

  Will Crider and Charlie Burge

  Pocket knives are operated outside of manufacturer recommendations on a regular basis. Misuse sometimes leads to blade fracture. This study was completed to determine if a passive design change or end-user correction exists that allows for a knife to be misused, without resulting in blade fracture. Simply, the study aimed to determine if the maximum stress could be mitigated. A finite element analysis (FEA) was conducted that imitated real-world twisting and prying effects on the blade of a Gerber Paraframe Mini – fine edge. It was suggested that prying more than 0.75 in away from the tip and twisting more than 0.375 in away from the tip could salvage the blade before fracture. The blade material was changed from 420 stainless steel to D2 tool steel. This offered very little mitigation and was only suggested for very specific applications.