Design for NVH: topology optimization of an engine bracket support

Noise Vibration and Harshness (NVH) issues are proven to be the main drivers for customer dissatisfaction in the latest years. This work relies on the framework of Design For X (DFX), specifically, Design for NVH. Main goal of this work was to perform a Topology Optimization (TO) of an engine bracket based on its vibrational behavior, in order to reduce the vibrations transmitted from the engine to the chassis and, consequently, improving the comfort for passengers. In particular, the target function was defined with the aim of increasing the first natural frequency of the bracket, whereas the bracket mass reduction was considered as a constraint function for the TO process. The vibrational characterization of the bracket was based on Frequency Response Function (FRF) analyses which, conducted via FEM (Finite Element Method), allowed to identify the resonant frequencies of the different bracket configurations built up during the TO. The FEM models included the cylinder head, with the related engine bracket support under optimization; the latter is connected to the bracket on which the simulation load was applied. The TO turned out to be effective in lowering the mass of engine bracket support of nearly 20% and, at the same time, increasing the first natural frequency of nearly 10%, this latter result was sufficient to guarantee an improvement of the comfort for passengers

BEM Simulation and Experimental Test of a FML Full Scale Aeronautic Panel Undergoing Biaxial Static Load

This paper concerns the numerical and experimental characterization ofthe static and fatigue strength of a flat stiffened panel, designed as a fiber metal laminates (FML) and made of Aluminum alloy and Fiber Glass FRP. The panel is full scale and was tested under both static and fatigue biaxial loads, applied by means of an in house designed and built multi-axial fatigue machine. The static test is simulated by the Boundary Element Method (BEM) in a two-dimensional approach (only allowance for membrane stresses). The strain gauge outcomes are compared with corresponding numerical results, getting a satisfactory correlation. After the static test, an initial notch is created in the panel and the aforementioned biaxial fatigue load is applied, causing a crack initiation and propagation; the related experimental initiation times and crack growth rates are provided

Probabilistic Analysis of Fatigue Behavior of Single Lap Riveted Joints

This research deals with the fatigue behavior of 200 small single lap multiple-riveted joint specimens, widely used for aeronautic structures. The tests were performed with three different levels of stress with stress ratio R = 0.05; three levels were set: 90 MPa, 120 MPa and 160 MPa. The fatigue life and critical crack size for all tested specimens were analyzed. According to the results’ analysis, two types of fracture, through-hole and in proximity of the hole, were observed, depending on the level of stress: the higher the applied stress, the more through-hole cracking. Indeed, under the fatigue load with a stress level of 90 MPa, less than 30% of specimens showed cracks propagating through the hole, while, at the stress level of 120 MPa, the percentage reaches 36.3%. At the stress level of 160 MPa, 100% of specimens failed through the hole. Moreover, aimed to use experimental data for probabilistic methods, a statistical analysis was performed according to the Anderson–Darling test. This method allowed the analysis of the datasets, in terms of both fatigue life and critical crack size, providing information about the best distribution function able to fit experimental results

Numerical evaluation of temperature fields and residual stresses in butt weld joints and comparison with experimental measurements

This paper presents a novel numerical model, based on the finite element (FE) method, for the simulation of a welding process aimed to make a twopass V-groove butt joint, paying attention on the prediction of residual stresses and distortions. The ‘element birth and death’ technique for the simulation of the weld filler supply has been considered within this paper. The main advancements with respect to the state of the art herein proposed concern: (i) the development of a modelling technique able to simulate the plates interaction during the welding operation when an only plate is modelled. This phenomenon is usually neglected in literature; (ii) the heat amount is supplied to the FEs as volumetric generation of the internal energy, allowing overcoming the time-consuming calibration phase needed to use the Goldak's model, commonly adopted in literature. Predicted results showed a good agreement with experimental ones

Analisi FEM di un piede piatto

La patologia del piattismo dell’arco plantare comporta una distribuzione non uniforme dei carichi, rispetto ad un piede sano, dando luogo a disallineamenti del bacino e ad atteggiamenti cifotici e/o scoliotici. Il presente lavoro riguarda l’analisi FEM di un piede affetto da tale patologia. Il modello numerico è stato realizzato da TAC, mediante tecniche di Reverse Engineering di segmentazione della densità, definendo geometricamente la struttura ossea e i tessuti morbidi. Successivamente è stata impiegata la modellazione CAD per la defi nizione geometrica delle cartilagini e per un affi namento del modello stesso

Dies for pressing metal powders to form helical gears

Abstract This work concerns the realization of dies to produce helical gears by metal powder compaction. Due to the helicoidal geometry of the cylindrical gears, the punch, in addition to the axial motion, must necessarily rotate to "cross" the die. The innovative idea is to design a perfectly functioning system that can generate any helix angle (β) in the range of interest 0°-30°, using the simple contact between punch and die cavity during the rotation. First of all, the punch-die system was treated as a self-locking screw to determine the maximum s-value at which punch could be clamped inside the die during pressing. The analysis encouraged the execution of experimental tests related to a die with β = 5°, obtaining excellent results. Subsequently, FEM (Finite Element Method) analyses were performed on the static behavior of the die, subjected to the pressures exerted by powder and shrink-fitting ring, for three different β-values: 5°, 18° and 30°. The results obtained for the latter two angles were compared with those related to the die with β equal to 5°, considered valid thanks to experimentation, in order to theoretically verify the correct functioning even of dies with larger angles

Structural and Vibro-Acoustics Optimization of a Car Body Rear Part

The perceived vibro-acoustic comfort, inside the passenger compartment, under driving conditions, is strictly related to the car body torsional behavior. The aim of this work was to identify which parts of a car body most influence the first torsional mode, in order to modify them and acquire an increase in such car body natural frequency. It was also intended to exploit the great potential of 3D printing that allows an increase in the complexity of component shapes, with an acceptable compromise with respect to production costs. A design and material (from steel to aluminum) change of a car body rear part, which was identified as the structural part of the car body with the most relevant impact on the frequency of the first torsional mode, was assessed in terms of structural and vibro-acoustic performances. In particular, with the constraint of increasing the structural and vibroacoustic performances and, at the same time, minimize the weight of the structure itself, geometric, structural (e.g., type of connections), and material changes of the car body rear part were assessed. Working on a car model dating back to 2008, which was already compliant with structural and vibro-acoustic regulatory norms, an increase of 2 Hz on the first torsional mode frequency of the Trimmed Body model was obtained. In parallel, a weight reduction in the optimized components was also gained. It was also requested to lower the cabin sound pressure levels, optimizing the vibro-acoustic transfer functions from the accelerations at engine mounts and suspension attachment points to the cabin inside. It was shown how the combined use of advanced topological and structural optimization tools, with the capabilities of an unconventional manufacturing technology, such as 3D printing in aluminum, could guarantee an increase in the vibro-acoustics and structural car performances, also gaining a weight reduction

Influences of Material Variations of Functionally Graded Pipe on the Bree Diagram

The present research is concerned with the elastic–plastic responses of functionally graded material (FGM) pipe, undergoing two types of loading conditions. For the first case, the FGM is subjected to sustained internal pressure combined with a cyclic bending moment whereas, in the second case, sustained internal pressure is applied simultaneously with a cyclic through-thickness temperature gradient. The properties of the studied FGM are considered to be variable through shell thickness according to a power-law function. Two different designs of the FGM pipe are adopted in the present research, where the inner surface in one case and the outer surface in the other are made from pure 1026 carbon steel. The constitutive relations are developed based on the Chaboche nonlinear kinematic hardening model, classical normality rule and von Mises yield function. The backward Euler alongside the return mapping algorithm (RMA) is employed to perform the numerical simulation. The results of the proposed integration procedure were implemented in ABAQUS using a UMAT user subroutine and validated by a comparison between experiments and finite element (FE) simulation. Various cyclic responses of the two prescribed models of FGM pipe for the two considered loading conditions are classified and brought together in one diagram known as Bree’s diagram

Probabilistic Analysis of Fatigue Behavior of Single Lap Riveted Joints

This research deals with the fatigue behavior of 200 small single lap multiple-riveted joint specimens, widely used for aeronautic structures. The tests were performed with three different levels of stress with stress ratio R = 0.05; three levels were set: 90 MPa, 120 MPa and 160 MPa. The fatigue life and critical crack size for all tested specimens were analyzed. According to the results’ analysis, two types of fracture, through-hole and in proximity of the hole, were observed, depending on the level of stress: the higher the applied stress, the more through-hole cracking. Indeed, under the fatigue load with a stress level of 90 MPa, less than 30% of specimens showed cracks propagating through the hole, while, at the stress level of 120 MPa, the percentage reaches 36.3%. At the stress level of 160 MPa, 100% of specimens failed through the hole. Moreover, aimed to use experimental data for probabilistic methods, a statistical analysis was performed according to the Anderson–Darling test. This method allowed the analysis of the datasets, in terms of both fatigue life and critical crack size, providing information about the best distribution function able to fit experimental results