Search results

Pores and shrink holes are unavoidable defects in the die-casting mass production process which may significantly influence the strength, fatigue and fracture behaviour as well as the life span of structures, especially if they are subjected to high static and dynamic loads. Such defects should be considered during the design process or after production, where the defects could be detected with the help of computed tomography (CT) measurements. However, this is usually not done in today's mass production environments. This paper deals with the stress analysis of die-cast structural parts with pores found from CT measurements or that are artificially placed within a structure.

In this paper the authors illustrate two general methodologies to take into account the porosity of die-cast components in the stress analysis. The detailed geometry of a die-cast part including all discontinuities such as pores and shrink holes can be included via STL data provided by CT measurements. The first approach is a combination of the finite element method (FEM) and the finite cell method (FCM), which extends the FEM if the real geometry cuts finite elements. The FCM is only applied in regions with pores. This procedure has the advantage that all simulations with different pore distributions, real or artificial, can be calculated without changing the base finite element mesh. The second approach includes the pore information as STL data into the original CAD model and creates a new adapted finite element mesh for the simulation. Both methods are compared and evaluated for an industrial problem.

The STL data of defects which the authors received from CT measurements could not be directly applied without repairing them. Therefore, for FEM applications an appropriate repair procedure is proposed. The first approach, which combines the FEM with the FCM, the authors have realized within the commercial software tool Abaqus. This combination performs well, which is demonstrated for test examples, and is also applied for a complex industrial project. The developed in-house code still has some limitations which restrict broader application in industry. The second pure FEM-based approach works well without limitations but requires increasing computational effort if many different pore distributions are to be investigated.

A new simulation approach which combines the FEM with the FCM has been developed and implemented into the commercial Abaqus FEM software. This approach the authors have applied to simulate a real engineering die-cast structure with pores. This approach could become a preferred way to consider pores in practical applications, where the porosity can be derived either from CT measurements or are artificially adopted for design purposes. The authors have also shown how pores can be considered in the standard FEM analysis as well.

Piezoelectric actuators and sensors are an invaluable part of lightweight designs for several reasons. They can either be used in noise cancellation devices as thin‐walled structures are prone to acoustic emissions, or in shape control approaches to suppress unwanted vibrations. Also in Lamb wave based health monitoring systems piezoelectric patches are applied to excite and to receive ultrasonic waves. The purpose of this paper is to develop a higher order finite element with piezoelectric capabilities in order to simulate smart structures efficiently.

In the paper the development of a new fully three‐dimensional piezoelectric hexahedral finite element based on the p‐version of the finite element method (FEM) is presented. Hierarchic Legendre polynomials in combination with an anisotropic ansatz space are utilized to derive an electro‐mechanically coupled element. This results in a reduced numerical effort. The suitability of the proposed element is demonstrated using various static and dynamic test examples.

In the current contribution it is shown that higher order coupled‐field finite elements hold several advantages for smart structure applications. All numerical examples have been found to agree well with previously published results. Furthermore, it is demonstrated that accurate results can be obtained with far fewer degrees of freedom compared to conventional low order finite element approaches. Thus, the proposed finite element can lead to a significant reduction in the overall numerical costs.

To the best of the author's knowledge, no piezoelectric finite element based on the hierarchical‐finite‐element‐method has yet been published in the literature. Thus, the proposed finite element is a step towards a holistic numerical treatment of structural health monitoring (SHM) related problems using p‐version finite elements.

The paper presents a new technique for a compatible transition from a h‐refined to a p‐refined finite element mesh. At one or more faces of particularly designed pNh‐transition elements a low order h‐discretization may be combined with a usual p‐mesh in the other parts of the elements. The pNh‐elements are conform finite elements which can be applied in an adaptive scheme controlled by a residue based error estimate. Typical applications which require strongly a local mesh refinement within a p‐finite element mesh are, e.g. the approximation of high gradients and the determination of contact areas. Numerical examples demonstrate the efficiency of the pNh‐element technique for such problems.