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The brake system is a critical item of safety equipment in a vehicle and provides the driver with adequate control over the speed of the vehicle and is classified as one of the most crucial parts in any vehicle. Rotor reliability and the thermal behaviour of various small scale disc brake rotors were investigated using a small scale brake dynamometer rig and a number of different numerical approaches. Abaqus and Matlab software were firstly used to construct a one dimensional (1D) thermal model to investigate the thermal performance of disc brakes. The 1D model was validated with literature and experimental results.

Customer Papers

During pressure testing of a large distributor the weld securing the bulkhead failed, which triggered large pressure transients and cavitation phenomena. The problem has been studied by explicit integration, using shell elements for the structural parts and acoustic elements for the water. Although the calculations had to be carried out in the absence of any information about the outcome of the accident, very good consistency was achieved between the predictions and the actual observations.

Customer Papers

Reduction of cogging torque is one of the fundamental goals in designing permanent magnet machines. Finite element analyses are indispensible in analyzing the various design choices for reducing cogging torque and for faster prototyping of the final product. In this Technology Brief, we show how Abaqus/Standard can be used to compute cogging torque in a permanent magnet generator. To reduce numerical noise, meshing techniques involving a sliding mesh and repeated meshes are realized using the advanced meshing functionality available in Abaqus/CAE.

Tech Notes

Modeling thermal behavior of Li-ion cells for vehicle electrification applications is a challenging task. AVL has developed 3D-FEA models to simulate the electro-thermal behavior of Li-ion battery cells with various geometries using Abaqus. In these models, the Li-ion battery system is simplified and modeled as heterogeneous solid medium consisting of a single or multiple equivalent battery layers with composite electrical and thermal conductivities for the equivalent anode, cathode and separator. Thermal behaviors of cylindrical, prismatic and pouch Li-ion battery cells and modules were analyzed under different electrical loads and cooling conditions.

Customer Papers

Sometime vise jaw holders of the hacksaw are broken due to accidental heavy loads or machine misusing. These broken part are the stationary and movable vise jaw holders and the connecter power screw between them. With the aim of investigating the failure of these components, a three dimensional finite element model for stress analysis has been performed. It starts by identifying the broken parts of the hacksaw machine. In addition, the material of the broken parts is identified, the CAD model is built, and the hacksaw mechanism is analyzed to get the accurate applied loads on the broken parts. After analyzing the model using Abaqus CAE software, the results show that the location of the high stresses are identical with the original broken parts.

Customer Papers

Pumping equipment is used in oil refining plants to pump oil distillation products. This equipment has to withstand heavy combined hydrodynamic and thermal loads, and recently been reported to fail due to fatigue damage. The main problem appears to be crack growth on peripheral wheel parts. The wheel sustains fatigue damage in an accumulation period which is shorter than the maintenance period recommended by the manufacturer. A study of the wheel fatigue life has been conducted. A material investigation was also carried out to verify that the damage had indeed been caused by fatigue. An analytical solution developed is viable for crack growth study only, and cannot predict fatigue life.

Customer Papers

This paper is a summary of finite element modeling approach used in the project for SC@UM Strengthening CFRP Challenge at FRPRCS-11. The modeling competition is to predict the behavior of a T-shaped reinforced concrete beam, shear and flexural strengthened with carbon reinforced polymer (CFRP) laminates according to the Near Surface Mounted (NSM) technique. A complete 3D Abaqus model was constructed to simulate the load displacement response of the CFRP laminates strengthened T-shaped reinforced concrete beam. Abaqus concrete damaged plasticity material model was employed to model concrete cracking/crushing failure. Embedded element was used to model concrete-rebar interaction.

Customer Papers

Presently the problem of safety providing of NPP under aircraft crash (AC) has special importance, because rather often floor response spectra (FRS) obtained in the AC analysis are dominant with respect to spectra, obtained in other special dynamic loadings, such as seismic load and explosive wave. In this paper we suggest approach, which gives an opportunity to change global Rayleigh damping matrix on global modal damping matrix, that previously was determined by special way. Also in this paper we represent results of the analysis of test model and of the real example, where authors represent significant diminishing of spectral accelerations in case of changing Rayleigh global damping matrix on modal global damping matrix.

Customer Papers

A study of screw pullout from cortical bone has been conducted using the UDMGINI subroutine with the extended finite element method (XFEM). XFEM alleviates mesh dependency when computationally modeling crack initiation and propagation. Cortical bone is a naturally occurring composite with a distinctive aligned microstructure that leads to anisotropic material behavior and damage. In this study, using a UDMGINI subroutine, stress components relative to a predefined osteon orientation were computed and an anisotropic damage criterion was used to determine damage initiation and to predict crack propagation. A 2D model of a single screw embedded in cortical bone was generated. A displacement boundary condition was applied to the top surface of the screw.

Customer Papers

A power generation toggle from the conventional sources to the becoming rapidly prioritisable renewable energy production poses a challenge for the fossil fired power plants. The strong dependency on the weather conditions makes such issues as e.g. non-predictable availability and variable loading to the ad hoc asset management tasks in terms of increasing operational flexibility. The paper focuses on the results of this tendency and their impact on the backbone of all power plants - power plant equipment –suffering from the accelerated accumulation of the combined creep-fatigue damage because of the more and more tightened transient start-up and shutdown conditions, increased heating rates and number of operational cycling.

Customer Papers

FE modeling of high duty bolted joints, such as those found in wind-turbines, is in many aspects a very complex task. On the one hand, the bolt analysis must comply with standardized guidelines, such as VDI 2230. On the other hand, FE models are usually highly detailed and contain a large number of bolt connections. This makes the whole design process error-prone and cumbersome for the FE engineer, since modeling all these connections by hand usually takes a large amount of time and diligence.

Customer Papers

The integrity of a nuclear waste burial site must be maintained for several millenia. The physical processes taking place at an underground disposal facility include seepage, heat transfer, and material swelling. These processes induce stress in the waste containment structure and must be understood in order to develop long-term disposal schemes. In this Technology Brief we show how the coupled multi-physics simulation capabilities of Abaqus/Standard can be used to analyze design options for nuclear waste burial.

Tech Notes