Browsing by Author "West, Robert L."

Now showing 1 - 20 of 99
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    Active Force Correction of Off-Nominal Structures Using Intelligent Scaffolding
    Everson, Holly Kathleen (Virginia Tech, 2024-10-17)
    The culmination of this research focuses on the area of structural support and stability as it relates to the field of large space structures. Fitting into the branch of in-space assembly, servicing, and manufacturing (ISAM), this topic covers essential subject matter areas of robotic manipulation, repair, state estimation, and structural health. As the next generation of space structures includes increased areas of modularity, the nature of structures built in-space lends itself significantly to repair efforts. With plans for these repair efforts in place, the lifetime of damaged structures can be greatly extended leading to a greater chance of mission success. By considering how repair efforts factor into the assembly scope, critical failures in large trusses, especially those involving single-point structural failures, can be mitigated. To do this, external forces are applied to the damaged structure utilizing an intelligent scaffolding formulation. This methodology employs robots to strategically apply loads to re-route abnormal stress and strain paths, correct for resulting deflections, and stabilize the structure itself. These tasks are vital to the safety of the structure and must take place before any repair efforts are considered in an effort to prevent cascading damage. The following research explores this damage simulation and correction paradigm through a variety of truss initial conditions, which allow for a suite of deflection responses. Utilizing these deflection responses a safe path for applying loads incrementally through generated waypoints is created with the help of the finite element modeler Ansys and a Python script. The ability for this system to successfully realign the wide scope of truss cases showcases that it is a truly adaptive system. Although this work is primarily proven within a simulation space, efforts to contextualize in a physical system and explore the elements needed to implement this method are also described. Finally, although this research is presented within the scope of damage repair, the final chapter looks to apply this method to other similarly unsupported structures by examining how critical it can be during assembly scenarios.
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    Anomaly detection in rolling element bearings via two-dimensional Symbolic Aggregate Approximation
    Harris, Bradley William (Virginia Tech, 2013-05-26)
    Symbolic dynamics is a current interest in the area of anomaly detection, especially in mechanical systems.  Symbolic dynamics reduces the overall dimensionality of system responses while maintaining a high level of robustness to noise.  Rolling element bearings are particularly common mechanical components where anomaly detection is of high importance.  Harsh operating conditions and manufacturing imperfections increase vibration innately reducing component life and increasing downtime and costly repairs.  This thesis presents a novel way to detect bearing vibrational anomalies through Symbolic Aggregate Approximation (SAX) in the two-dimensional time-frequency domain.  SAX reduces computational requirements by partitioning high-dimensional sensor data into discrete states.  This analysis specifically suits bearing vibration data in the time-frequency domain, as the distribution of data does not greatly change between normal and faulty conditions. Under ground truth synthetically-generated experiments, two-dimensional SAX in conjunction with Markov model feature extraction is successful in detecting anomalies (> 99%) using short time spans (< 0.1 seconds) of data in the time-frequency domain with low false alarms (< 8%).  Analysis of real-world datasets validates the performance over the commonly used one-dimensional symbolic analysis by detecting 100% of experimental anomalous vibration with 0 false alarms in all fault types using less than 1 second of data for the basis of 'normality'. Two-dimensional SAX also demonstrates the ability to detect anomalies in predicative monitoring environments earlier than previous methods, even in low Signal-to-Noise ratios.
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    Application of Multi-Port Mixing for Passive Suppression of Thermo-Acoustic Instabilities in Premixed Combustors
    Farina, Jordan T. (Virginia Tech, 2013-03-29)
    The utilization of lean premixed combustors has become attractive to designers of industrial gas turbines as a means of meeting strict emissions standards without compromising efficiency.  Mixing the fuel and air prior to combustion allows for lower temperature flame zones, creating the potential for drastically reduced nitrous oxide emissions.  While effective, these systems are commonly plagued by combustion driven instabilities.  These instabilities produce large pressure and heat release rate fluctuations due to a resonant interaction between the combustor acoustics and the flame.  A primary feedback mechanism responsible for driving these systems is the propagation of Fuel/Air Ratio (FAR) fluctuations into the flame zone.  These fluctuations are formed inside of the premixing chamber when fuel is injected into and mixed with an oscillating air flow. The research presented here aimed to develop new technology for premixer designs, along with an application strategy, to avoid resonant thermo-acoustic events driven by FAR fluctuations.  A passive fuel control technique was selected for investigation and implementation. The selected technique utilized fuel injections at multiple, strategically placed axial locations to target and inhibit FAR fluctuations at the dominant resonant mode of the combustor.  The goal of this research was to provide an understanding of the mixing response inside a realistic premixer geometry and investigate the effectiveness of the proposed suppression technique. The mixing response was investigated under non-reacting flow conditions using a unique modular premixer.  The premixer incorporated variable axial fuel injection locations, as well as interchangeable mixing chamber geometries.  Two different chamber designs were tested: a simple annular chamber and one incorporating an axial swirler.  The mixing response of the simple annular geometry was well characterized, and it was found that multiple injections could be effectively configured to suppress the onset of an unstable event at very lean conditions. Energy dense flame zones produced at higher equivalence ratios, however, were found to be uncontrollable using this technique. Additionally, the mixing response of the swirl geometry was difficult to predict. This was found to be the result of large spatial gradients formed in the dynamic velocity field as acoustic waves passed through the swirl vanes.
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    Applications of Vibration-Based Occupant Inference in Frailty Diagnosis through Passive, In-Situ Gait Monitoring
    Goncalves, Rafael dos Santos (Virginia Tech, 2021-08-30)
    This work demonstrates an application of Vibration-Based Occupant Inference (VBOI) in frailty analysis. The rise of both Internet-of-Things (IoT) and VBOI provide new techniques to perform gait analysis via footstep-induced vibration which can be analyzed for early detection of human frailty. Thus, this work provides an application of VBOI to passively track gait parameters (e.g., gait speed) using floor-mounted accelerometers as opposed to using a manual chronometer as it is commonly performed by healthcare professionals. The first part of this thesis describes the techniques used for footstep detection by measuring the power of the footstep-generated vibration waves. The extraction of temporal gait parameters from consecutive footsteps can then be used to estimate temporal features such as cadence and stride time variation. VBOI provides many algorithms to accurately detect when a human-induced vibration event happened, however, spatial information is also needed for many gait parameters used in frailty diagnosis. Detecting where an event happened is a complicated problem because footsteps waves travel and decay in different ways according to the medium (floor system), the number of people walking, and even the walking speed. Therefore, the second part of this work will utilize an energy-based approach of footstep localization in which it is assumed that footstep waves decay exponentially as they travel across the medium. The results from this approach are then used to calculate spatial and tempo-spatial parameters. The main goal of this study is to understand the applicability of VBOI algorithms in gait analysis for frailty detection in a healthcare setting.
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    Applying the Principles of Project Management to a Collegiate Automotive Engineering Design Project
    Dvorkin, William Nathan (Virginia Tech, 2016-06-08)
    The Hybrid Electric Vehicle Team of Virginia Tech is a collegiate automotive engineering design team that reengineers production vehicles to reduce environmental impact while maintaining vehicle marketability. The team Project Manager is responsible for coordinating high-level management and planning activities with the goal of better aligning the team with business and automotive industry practices. Project management responsibilities within the Hybrid Electric Vehicle Team are divided into four categories: human resource management, schedule management, cost management, and risk management. This document outlines how project management strategies were researched and adapted from industry practices for use by the Hybrid Electric Vehicle Team in achieving its goals. The human resource management strategy adopts onboarding principles that better prepare new students to become effective team members. By restructuring the organization and incorporating onboarding strategies, annual turnover is reduced from 71% to 44%. The decrease in turnover is enabled by the successful creation of an independent study program which trains newcomers to become effective team members. The program can be improved for the future by further developing the curriculum. The employed schedule management strategy develops the project schedule iteratively as technical information reveals itself through task progress. Utilizing this process makes schedule management possible in an environment with incomplete information and pressing deadlines. This strategy experienced limited success due to the lack of team and project scheduling experience on behalf of several key members of the process. The cost management strategy is designed to gather detailed financial data to perform an earned-value analysis and create improved budgets. By understanding income and expense patterns, the Project Manager can create economic forecasts to determine the economic viability of the team. The strategy was successfully implemented and allowed the team to gather valuable financial data. The risk management strategy identifies and quantifies technical risks associated with vehicle development. By focusing more resources on high-risk activities, the team can improve preparation for competition where the vehicle is judged according engineering quality and build progress. The strategy was successful because it identified critical hazards to the project schedule and scope, but can be improved by broadening the process to account for a wider variety of risks.
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    Automatic generation of interference-free geometric models of spatial mechanisms
    Keil, Mitchel J. (Virginia Tech, 1990)
    This work presents methods used to obtain geometric models of spatial mechanisms which can be realized in hardware. Each model is created automatically from the kinematic description of a mechanism. The models are tested for interference between joints and links. Models with interfering links or joints are reshaped automatically into an interference-free configuration. An investigation of the relative efficiency of different interference detection techniques is discussed. A method for determining interferences based on vector loop equations was developed for this work. Other approaches for interference detection include parametric space and a method using parallel coordinates. 2000 line segments were randomly generated to test the three methods. No significant difference between the three techniques was found, but a coarse detection scheme was developed based on observations of intersection conditions in parallel coordinates. The coarse detection technique reduced interference detection times by 48%. The concept of joint positioning freedoms is presented formally for the first time. Using a unidirectional avoidance strategy along a straight line, these repositioning freedoms are exploited in a manner which guarantees the elimination of interferences for revolute, prismatic, and cylindric joints. A unique method for optimal orientation of spheric joint ball-cup pairs is described. Points from an inverse image of the attachment piece for the ball are mapped onto a unit sphere in the reference frame of the cup. The axis of a bounding cone is then used to align the attachment piece for the cup. The method minimizes the chances for collisions between the cup and the ball attachment piece. Elements which attach the joints are modeled as three segments. This has proven to be an optimal representation. Interferences with these elements are eliminated using the elliptical projection of circular paths onto a plane which is perpendicular to the axis of symmetry for an intruding object. Several examples are given illustrating the successful generation of interference-free spatial mechanism models. The mechanisms include an RSSR, an RPCS, an RCCC, and an RRRRRRR.
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    Binder-Powder Interaction: Investigating the Process-Property Relations in Metal Binder Jetting
    Rahman, Kazi Moshiur (Virginia Tech, 2023-01-27)
    Binder jetting (BJT) is a powder bed based additive manufacturing (AM) process where the interaction of inkjetted droplets of a binder and particles in the powder bed create 3D geometries in a layerwise fashion. The fabricated green parts are usually thermally post-processed for densification and strengthening. BJT holds distinct advantages over other AM processes as it can fabricate parts with virtually any materials (metals, ceramics, and polymers) in a fast and cost-effective way, while achieving isotropic material properties in the parts. However, broad adoption of this process for production is still lagging, partially due to the lack of repeatable part quality, which largely stems from the limited understanding of the process physics, namely binder-powder (B/P) interaction. To bridge this knowledge gap, it is necessary to understand the implications of B/P interaction on process-structure-property relationships and discover ways to achieve new functionalities for enhanced properties. Thus, this research is broadly focused in establishing understanding in (i) binder-powder interaction and (ii) the impact of binder on part densification. Prior studies have focused on the effects of powder interaction with micro/meso-scale binder droplets, despite commercial BJT systems featuring picoliter-scale droplets. These studies have explored the effects of B/P interaction on printed primitive formation, but it's implication on final part properties have not been studied. In this work, the effects of particle size distribution and droplet size variation on final part properties are explored. Additionally, the effects of B/P interaction on accuracy and the resolution of the printed parts are investigated. Densification of parts is a primary focus of many BJT studies as it dictates the final part properties and is influenced by factors from both the printing process and post-processing treatments. Binder plays an integral role in the shaping of parts and maintaining part integrity until densification through sintering. Prior studies on the effects of binder content on densification are inclusive. In this work, a new approach termed as "shell printing" is introduced to vary the binder content in the parts. The process-structure-properties influenced by this approach are investigated. It was found that binder hinders densification, and through the selective variation of binder content throughout the part volume, this new approach is introduced as a means for enhancing part properties. Finally, the insights from the impact of binder on densification are leveraged to create an anti-counterfeiting tagging strategy by controlling the pores and grain microstructures inside a part. In this novel approach, binder concentration is controlled in a manner that the stochastically formed pores are clustered to create a designed domain that represents a secret 'tag' within the part volume. The created tagging domains, and the feature resolvability of this approach are investigated through metallographic characterization and non-destructively evaluated through micro-computed tomography.
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    Burnthrough Modeling of Marine Grade Aluminum Alloy Structural Plates Exposed to Fire
    Rippe, Christian M. (Virginia Tech, 2015-11-13)
    Current fire induced burnthrough models of aluminum typically rely solely on temperature thresholds and cannot accurately capture either the occurrence or the time to burnthrough. This research experimentally explores the fire induced burnthrough phenomenon of AA6061-T651 plates under multiple sized exposures and introduces a new burnthrough model based on the near melting creep rupture properties of the material. Fire experiments to induce burnthrough on aluminum plates were conducted using localized exposure from a propane jet burner and broader exposure from a propane sand burner. A material melting mechanism was observed for all localized exposures while a material rupture mechanism was observed for horizontally oriented plates exposed to the broader heat flux. Numerical burnthrough models were developed for each of the observed burnthrough mechanisms. Material melting was captured using a temperature threshold model of 633 deg C. Material rupture was captured using a Larson-Miller based creep rupture model. To implement the material rupture model, a characterization of the creep rupture properties was conducted at temperatures between 500 and 590 deg C. The Larson-Miller curve was subsequently developed to capture rupture behavior. Additionally, the secondary and tertiary creep behavior of the material was modeled using a modified Kachanov-Rabotnov creep model. Thermal finite element model accuracy was increased by adapting a methodology for using infrared thermography to measure spatially and temporally varying full-field heat flux maps. Once validated and implemented, thermal models of the aluminum burnthrough experiments were accurate to 20 deg C in the transient and 10 deg C in the steady state regions. Using thermo-mechanical finite element analyses, the burnthrough models were benchmarked against experimental data. Utilizing the melting and rupture mechanism models, burnthrough occurrence was accurately modeled for over 90% of experiments and modeled burnthrough times were within 20% for the melting mechanism and 50% for the rupture mechanism. Simplified burnthrough equations were also developed to facilitate the use of the burnthrough models in a design setting. Equations were benchmarked against models of flat and stiffened plates and the burnthrough experiments. Melting mechanism burnthrough time results were within 25% of benchmark values suggesting accurate capture of the mechanism. Rupture mechanism burnthrough results were within 60% of benchmark values.
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    A Computational and Experimental Study on the Electrical and Thermal Properties of Hybrid Nanocomposites based on Carbon Nanotubes and Graphite Nanoplatelets
    Safdari, Masoud (Virginia Tech, 2012-12-13)
    Carbon nanotubes (CNTs) and graphite nanoplatelets (GNPs) are carrying great promise as two important constituents of future multifunctional materials. Originating from their minimal defect confined nanostructure, exceptional thermal and electrical properties have been reported for these two allotropic forms of carbon. However, a brief survey of the literature reveals the fact that the incorporation of these species into a polymer matrix enhances its effective properties usually not to the degree predicted by the composite\\textquoteright s upper bound rule. To exploit their full potential, a proper understanding of the physical laws characterizing their behavior is an essential step. With emphasis on the electrical and thermal properties, the following study is an attempt to provide more realistic physical and computational models for studying the transport properties of these nanomaterials. Originated from quantum confinement effects, electron tunneling is believed to be an important phenomenon in determining the electrical properties of nanocomposites comprising CNTs and GNPs. To assess its importance, in this dissertation this phenomenon is incorporated into simulations by utilizing tools from statistical physics. A qualitative parametric study was carried out to demonstrate its dominating importance. Furthermore, a model is adopted from the literature and extended to quantify the electrical conductivity of these nanocomposite. To establish its validity, the model predictions were compared with relevant published findings in the literature. The applicability of the proposed model is confirmed for both CNTs and GNPs. To predict the thermal properties, a statistical continuum based model, originally developed for two-phase composites, is adopted and extended to describe multiphase nanocomposites with high contrast between the transport properties of the constituents. The adopted model is a third order strong-contrast expansion which directly links the thermal properties of the composite to the thermal properties of its constituents by considering the microstructural effects. In this approach, a specimen of the composite is assumed to be confined into a reference medium with known properties subjected to a temperature field in the infinity to predict its effective thermal properties. It was noticed that such approach is highly sensitive to the properties of the reference medium. To overcome this shortcoming, a technique to properly select the reference medium properties was developed. For verification purpose the proposed model predictions were compared with the corresponding finite element calculations for nanocomposites comprising cylindrical and disk-shaped nanoparticles. To shed more light on some conflicting reports about the performance of the hybrid CNT/GNP/polymer nanocomposites, an experimental study was conducted to study a hybrid ternary system. CNT/polymer, GNP/polymer and CNT/GNP/polymer nanocomposite specimens were processed and tested to evaluate their thermal and electrical conductivities. It was observed that the hybrid CNT/GNP/polymer composites outperform polymer composites loaded solely with CNTs or GNPs. Finally, the experimental findings were utilized to serve as basis to validate the models developed in this dissertation. The experimental study was utilized to reduce the modeling uncertainties and the computational predictions of the proposed models were compared with the experimental measurements. Acceptable agreements between the model predictions and experimental data were observed and explained in light of the experimental observations. The work proposed herein will enable significant advancement in understanding the physical phenomena behind the enhanced electrical and thermal conductivities of polymer nanocomposites specifically CNT/GNP/polymer nanocomposites. The dissertation results offer means to tune-up the electrical and thermal properties of the polymer nanocomposite materials to further enhance their performance.
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    Computational and Machine Learning-Reinforced Modeling and Design of Materials under Uncertainty
    Hasan, Md Mahmudul (Virginia Tech, 2023-07-05)
    The component-level performance of materials is fundamentally determined by the underlying microstructural features. Therefore, designing high-performance materials using multi-scale models plays a significant role to improve the predictability, reliability, proper functioning, and longevity of components for a wide range of applications in the fields of aerospace, electronics, energy, and structural engineering. This thesis aims to develop new methodologies to design microstructures under inherent material uncertainty by incorporating machine learning techniques. To achieve this objective, the study addresses gradient-based and machine learning-driven design optimization methods to enhance homogenized linear and non-linear properties of polycrystalline microstructures. However, variations arising from the thermo-mechanical processing of materials affect microstructural features and properties by propagating over multiple length scales. To quantify this inherent microstructural uncertainty, this study introduces a linear programming-based analytical method. When this analytical uncertainty quantification formulation is not applicable (e.g., uncertainty propagation on non-linear properties), a machine learning-based inverse design approach is presented to quantify the microstructural uncertainty. Example design problems are discussed for different polycrystalline systems (e.g., Titanium, Aluminium, and Galfenol). Though conventional machine learning performs well when used for designing microstructures or modeling material properties, its predictions may still fail to satisfy design constraints associated with the physics of the system. Therefore, the physics-informed neural network (PINN) is developed to incorporate problem physics in the machine learning formulation. In this study, a PINN model is built and integrated into materials design to study the deformation processes of Copper and a Titanium-Aluminum alloy.
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    Computational Design of 2D-Mechanical Metamaterials
    McMillan, Kiara Lia (Virginia Tech, 2022-06-22)
    Mechanical metamaterials are novel materials that display unique properties from their underlying microstructure topology rather than the constituent material they are made from. Their effective properties displayed at macroscale depend on the design of their microstructural topology. In this work, two classes of mechanical metamaterials are studied within the 2D-space. The first class is made of trusses, referred to as truss-based mechanical metamaterials. These materials are studied through their application to a beam component, where finite element analysis is performed to determine how truss-based microstructures affect the displacement behavior of the beam. This analysis is further subsidized with the development of a graphical user interface, where users can design a beam made of truss-based microstructures to see how their design affects the beam's behavior. The second class of mechanical metamaterial investigated is made of self-assembled structures, called spinodoids. Their smooth topology makes them less prone to high stress concentrations present in truss-based mechanical metamaterials. A large database of spinodoids is generated in this study. Through data-driven modeling the geometry of the spinodoids is coupled with their Young's modulus value to approach inverse design under uncertainty. To see mechanical metamaterials applied to industry they need to be better understood and thoroughly characterized. Furthermore, more tools that specifically help push the ease in the design of these metamaterials are needed. This work aims to improve the understanding of mechanical metamaterials and develop efficient computational design strategies catered solely for them.
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    Computational Study of Highway Bridges Structural Response Exposed to a Large Fire Exposure
    Nahid, Mohammad N. (Virginia Tech, 2015-07-08)
    The exposure from a localized vehicle fire has been observed to produce excessive damage onto highway bridge structural elements including complete collapse of the infrastructure. The occurrence of a fire beneath a bridge can lead to significant economic expense and loss of service even if the bridge does not collapse. The focus of the current research is to assess and evaluate the effect of realistic localized fire exposures from vehicles on the bridge structural integrity and to guide future development of highway bridge design with improved fire resistance. In this research, the bridge structural element response was predicted through a series of three loosely coupled analyses: fire analysis, thermal analysis, and structural analysis. Two different types of fire modeling methodologies were developed in this research and used to predict the thermo-structural response of bridge structural elements: one to model the non-uniform exposure due to a vehicle fire and another to predict response due to a standard uniform furnace exposure. The vehicle fire scenarios required coupling the computational fluid dynamics (CFD) code Fire Dynamics Simulator (FDS) with Abaqus while the furnace exposure scenarios were all done within Abaqus. Both methodologies were benchmarked against experimental data. Using the developed methodologies, simulations were initially performed to predict the thermo-structural response of a single steel girder-concrete deck composite assembly to different local, non-uniform fires and uniform standard furnace fire exposures. The steel girder-concrete deck composite assembly was selected since it is a common bridge design. Following this, a series of simulations were performed on unprotected highway bridges with multiple steel plate girders and steel tub girders subjected to localized fires. The analyses were used to evaluate the influence of a fire scenario on the bridge element response, identify the factors governing the failure of bridge structural elements subjected to a localized fire exposure, and provide guidance in the design of highway bridge structural elements against fire hazards. This study demonstrates that girder geometry affected both the dynamics of the fire as well as the heat transfer to the bridge structural elements which resulted in a different structural response for the bridge. A heavy goods vehicle (heat release rate of 200 MW) and tanker fires (heat release rate of 300 MW) were predicted to cause the bridge to fail due to collapse, while smaller fires did not. The geometric features of the plate girders caused the girder elements to be exposed to higher heat fluxes from both sides of the girder resulting in collapse when exposed to a HGV fire. Conversely, the closed feature of the box girder does not allow the interior surfaces to be in direct contact with the flames and are only exposed to the internal reradiation from surfaces inside the girder. As a result, the single and double lane tub girder highway bridge structure does not fail due to a heavy goods vehicle fire exposure.
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    A Computer Vision Approach to Stress Determination in Blisters, and a Fatigue-Based Method Framework for Testing Defect Development
    Marthinuss, Samuel Joseph (Virginia Tech, 2020-11-24)
    With the development of hydrogen fuel cell technology continuing to advance, rapid characterization of membranes is increasingly important for design purposes. Pressurized blister testing has been suggested as an accelerated characterization alternative to traditional relative humidity (RH) cycling tests, and is the focus of this project. Prior efforts to determine the stress state present in the pressurized membrane blister test, however, have required constitutive properties of the membrane (Young's modulus and Poisson's ratio), along with Hencky's classic model for circular membrane stresses. Herein we describe an analysis method and computer vision imaging technique that are capable of determining the stress state in a pressurized circular membrane based solely on simple equilibrium equations and geometric considerations. This analysis method is applied to an image of the blister during testing, and the only additional required data is the pressure at the time the image was taken. By pressurizing circular blisters, an equi-biaxial, mechanical stress state is induced, simulating membrane stresses experienced during fuel cell operation as humidity levels fluctuate. The analysis leverages membrane theory and the axisymmetric geometry to determine the stress state from a profile image of the inflated blister. As a check for the method, an elastomer with known constitutive properties was analyzed using both the previous Hencky's solution method, as well as the new computer vision imaging method. The comparison of stress calculation results show that the two methods agree within 5 percent. A primary mechanism of membrane failure through mechanical stressors is the growth of local defects (usually chemically induced) due to the cyclic equi-biaxial stress state. In order to better understand and characterize the effect of disparate initial defects on CCM, two primary methods to defect membranes were introduced. The first was a compression against sandpaper method meant to simulate GDL compression, and the second was a targeted method using a hypodermic needle to initiate a defect at a central location on the membrane prior to pressurization. Observing the pressure decay in these defected blisters as compared to undefected tests showed that, while undefected samples did not experience pressure decay until failure, defected samples began showing signs of leaking through pressurization cycle profiles and steady state pressures achieved. Pressure data showed that samples tended to lose pressure more quickly with increasing initial defect severity. Undefected samples exhibited no pressure loss until the moment of failure, which was often catastrophic and instantaneous. Sandpaper defected samples exhibited a slow decay in cycle steady state pressure throughout tests, with no increase in cycle pressurization time. Needle samples showed a slow decay in cycle steady state pressure as well as an increase in time for the cycles to reach steady state. The needle defects were the most locally severe and thus the pressure decay indicators were most significant out of all the samples tested. The blister test method rapidly cycles mechanical stresses in a CCM, and elucidates signs of leaking that correlate to flaw development in recorded pressure data. With further development, it might serve as a robust method to quickly test flaw growth rate and development in CCM samples.
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    Crack path selection and shear toughening effects due to mixed mode loading and varied surface properties in beam-like adhesively bonded joints
    Guan, Youliang (Virginia Tech, 2014-01-17)
    Structural adhesives are widely used with great success, and yet occasional failures can occur, often resulting from improper bonding procedures or joint design, overload or other detrimental service situations, or in response to a variety of environmental challenges. In these situations, cracks can start within the adhesive layer or debonds can initiate near an interface. The paths taken by propagating cracks can affect the resistance to failure and the subsequent service lives of the bonded structures. The behavior of propagating cracks in adhesive joints remains of interest, including when some critical environments, complicated loading modes, or uncertainties in material/interfacial properties are involved. From a mechanics perspective, areas of current interest include understanding the growth of damage and cracks, loading rate dependency of crack propagation, and the effect of mixed mode fracture loading scenarios on crack path selection. This dissertation involves analytical, numerical, and experimental evaluations of crack propagation in several adhesive joint configurations. The main objective is an investigation of crack path selection in adhesively bonded joints, focusing on in-plane fracture behavior (mode I, mode II, and their combination) of bonded joints with uniform bonding, and those with locally weakened interfaces. When removing cured components from molds, interfacial debonds can sometimes initiate and propagate along both mold surfaces, resulting in the molded product partially bridging between the two molds and potentially being damaged or torn. Debonds from both adherends can sometimes occur in weak adhesive bonds as well, potentially altering the apparent fracture behavior. To avoid or control these multiple interfacial debonding, more understanding of these processes is required. An analytical model of 2D parallel bridging was developed and the interactions of interfacial debonds were investigated using Euler-Bernoulli beam theory. The numerical solutions to the analytical results described the propagation processes with multiple debonds, and demonstrated some common phenomena in several different joints corresponding to double cantilever beam configurations. The analytical approach and results obtained could prove useful in extensions to understanding and controlling debonding in such situations and optimization of loading scenarios. Numerical capabilities for predicting crack propagation, confirmed by experimental results, were initially evaluated for crack behavior in monolithic materials, which is also of interest in engineering design. Several test cases were devised for modified forms of monolithic compact tension specimens (CT) were developed. An asymmetric variant of the CT configuration, in which the initial crack was shifted to two thirds of the total height, was tested experimentally and numerically simulated in ABAQUS®, with good agreement. Similar studies of elongated CT specimens with different specimen lengths also revealed good agreement, using the same material properties and cohesive zone model (CZM) parameters. The critical specimen length when the crack propagation pattern abruptly switches was experimentally measured and accurately predicted, building confidence in the subsequent studies where the numerical method was applied to bonded joints. In adhesively bonded joints, crack propagation and joint failure can potentially result from or involve interactions of a growing crack with a partially weakened interface, so numerical simulations were initiated to investigate such scenarios using ABAQUS®. Two different cohesive zone models (CZMs) are applied in these simulations: cohesive elements for strong and weak interfaces, and the extended finite element method (XFEM) for cracks propagating within the adhesive layer. When the main crack approaches a locally weakened interface, interfacial damage can occur, allowing for additional interfacial compliance and inducing shear stresses within the adhesive layer that direct the growing crack toward the weak interface. The maximum traction of the interfacial CZM appears to be the controlling parameter. Fracture energy of the weakened interface is shown to be of secondary importance, though can affect the results when particularly small (e.g. 1% that of the bulk adhesive). The length of the weakened interface also has some influence on the crack path. Under globally mixed mode loadings, the competition between the loading and the weakened interface affects the shear stress distribution and thus changes the crack path. Mixed mode loading in the opposite direction of the weakened interface is able to drive the crack away from the weakened interface, suggesting potential means to avoid failure within these regions or to design joints that fail in a particular manner. In addition to the analytical and numerical studies of crack path selection in adhesively bonded joints, experimental investigations are also performed. A dual actuator load frame (DALF) is used to test beam-like bonded joints in various mode mixity angles. Constant mode mixity angle tracking, as well as other versatile loading functions, are developed in LabVIEW® for use with a new controller system. The DALF is calibrated to minimize errors when calculating the compliance of beam-like bonded joints. After the corrections, the resulting fracture energies ( ) values are considered to be more accurate in representing the energy released in the crack propagation processes. Double cantilever beam (DCB) bonded joints consisting of 6061-T6 aluminum adherends bonded with commercial epoxy adhesives (J-B Weld, or LORD 320/322) are tested on the DALF. Profiles of the values for different constant mode mixity angles, as well as for continuously increasing mode mixity angle, are plotted to illustrate the behavior of the crack in these bonded joints. Finally, crack path selection in DCB specimens with one of the bonding surfaces weakened was studied experimentally, and rate-dependency of the crack path selection was found. Several contamination schemes are attempted, involving of graphite flakes, silicone tapes, or silane treatments on the aluminum oxide interfaces. In all these cases, tests involving more rapid crack propagation resulted in interfacial failures at the weakened areas, while slower tests showed cohesive failure throughout. One possible explanation of this phenomenon is presented using the rate-dependency of the yield stress (commonly considered to be corresponding to the maximum traction) of the epoxy adhesives. These experimental observations may have some potential applications tailoring adhesive joint configurations and interface variability to achieve or avoid particular failure modes.
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    Curing Characteristics of Photopolymer Resin With Dispersed Glass Microspheres in Vat Polymerization 3D Printing
    Liang, Jingyu (Virginia Tech, 2023-07-07)
    The curing characteristics of photopolymer resin determine the relationship between the vat polymerization (VP) process parameters and the layer thickness, geometric accuracy, and surface quality of the 3D printed specimen. Dispersing filler material into the photopolymer resin changes its curing characteristics because the filler scatters and absorbs light, which modifies the curing reaction. However, the ability to cure photopolymer resin with high filler volume fraction is important to 3D print material specimens for specific engineering applications, e.g. structural polymer composite materials, electrical and thermal conductive materials, and ceramic materials for biological and high-temperature environments. We methodically measure the curing characteristics of diacrylate/epoxy photopolymer resin with dispersed glass microspheres. The experiments show that the curing depth, degree-of-cure, and surface roughness depend on both the light exposure dose and the filler fraction. We determine that the degree-of-cure increases with increasing filler fraction for constant exposure dose, and approaches 90% with increasing exposure dose, independent of the filler fraction. The geometric accuracy of the 3D printed specimens decreases with increasing exposure dose and with increasing filler volume fraction due to so-called profile broadening. Finally, we show that the average surface roughness of the 3D printed specimens decreases with increasing exposure dose and filler fraction. This work has implications for VP of photopolymer resins with high filler fraction.
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    Damping of Vibration Using Periodically Voided Viscoelastic Metamaterials
    Trevisan, Spencer Dunn (Virginia Tech, 2024-05-24)
    This thesis investigates the damping effects of a metamaterial, on structural vibration, by inducing periodic voids in the base damping material as opposed to infusing the damping material with other material. Metamaterials have been used previously to improve the damping of vibrational waves and acoustic waves through wave scattering and wave reflection at periodic impedance changes. Impedance changes can occur at both material boundaries and geometric changes of the medium. Impedance changes cause wave scattering, wave reflection, and changing of wave speed. The low frequency region of the vibration spectrum is generally harder to dampen due to the longer wavelengths. By slowing the waves down, the wavelength can be shortened and the viscoelastic material will be more effective at damping the waves. The metamaterial in the thesis has one, two, three, and four periodically located voids in the viscoelastic damping material to determine the effectiveness of the damping compared to the same beam with no damping material applied and the beam covered completely with the standard viscoelastic damping material. This research will include both finite element models of the beam and concept testing to explore the damping effects of the metamaterial.
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    Design and Additive Manufacturing of Carbon-Fiber Reinforced Polymer Microlattice with High Stiffness and High Damping
    Kadam, Ruthvik Dinesh (Virginia Tech, 2019-10-17)
    Carbon fiber reinforced polymer (CFRP) composites are known for their high stiffness-to-weight and high strength-to-weight ratios and hence are of great interest in several engineering fields such as aerospace, automotive and defense. However, despite their light weight, high stiffness and high strength, their application in these fields is limited due to their poor energy dissipation and vibration damping capabilities. This thesis presents a two-phase microlattice design to overcome this problem. To realize this design, a novel tape casting integrated multi-material stereolithography system is developed and mechanical properties of samples fabricated using this system are evaluated. The design incorporating a stiff phase (CFRP) and a high loss phase, exhibiting high stiffness as well as high damping, is studied via analytical and experimental approaches. To investigate its damping performance, mechanical properties at small-strain and large-strain regimes are measured through dynamic material analysis (DMA) and quasi-static cyclic compression tests respectively. It is seen that both intrinsic (small-strain) and structural (large-strain) damping in terms of a figure of merit (FOM), E1/3tanδ/ρ, can be enhanced by a small addition of a high loss phase in Reuss configuration. Moreover, it is seen that structural damping is improved at low relative densities due to the presence of elastic buckling during deformation. For design usefulness, tunability maps, displaying FOM in terms of design parameters, are developed by curve fitting of experimental measurements. The microlattice design is also evaluated quantitatively by comparing it with existing families of materials in a stiffness-loss map, which shows that the design is as stiff as commercial CFRP composites and as dissipative as elastomers.
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    Design and Analysis of an Innovative run-flat system for pneumatic tires
    Saraswat, Abhishek (Virginia Tech, 2024-10-21)
    Pneumatic tires have been an essential part of the automobile since the early 20th century. Providing load carrying, braking, accelerating and turning capability as well as a certain degree isolation from the road, they fail to function without the presence of air pressure inside them. Run-flat tire systems allow the vehicle to continue running with reduced driving speeds for a certain specified range in case of loss of air pressure due to puncture or damage. In this work, the design of self-supporting and insert supported run-flat systems was approached using CAE. Two tire FE models of sizes 175/70 R14 and 175/60 R18 were used in this study. All structural and thermal simulations were done using ABAQUS and ENDURICA software was used for fatigue life simulation. Distance travelled before failure was used as the primary parameter for design evaluation along with secondary parameters of contact patch area and contact pressure, tire temperature profiles and rolling resistance. Ride comfort and handling characteristics are important performance parameters for a tire. Thus, a limited study to quantify the effect of run-flat system on the ride and handling properties was also conducted. The target design values for maximum load were fixed according to ETRTO standards while the maximum operating speed and the desired mileage in deflated condition was fixed at 45 mph and 50 miles, respectively. The initial part of the design process for the auxiliary supported design involved using a rigid cylindrical structure of varying height and thickness as a rim-mounted run-flat insert to get estimate of life of tire structure for different levels of deformation. The results were then used as input for designing a deformable rim mounted insert using reinforced rubber material. For the self-supported design, the sidewall of the tire was modified to increase its section thickness from an average value of 5 mm in the original design to 10 mm and 15 mm by addition of rubber material. For each thickness value, three designs based on the location in the tire structure where the material addition began relative to the belt edges of the tire were created. The designs were compared in terms of their fatigue life and contact patch area. For both types of run-flat designs, a candidate design, which satisfied the performance criteria, was found using the simulation results for the tire and run-flat system. It was concluded that a simulation-based approach can be used to design innovative run-flat systems for pneumatic tires.
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    Design and Implementation of a Clutch and Brake System for a Single Wheel Indoor Tire Testing Rig
    Khan, Aamir Khusru (Virginia Tech, 2017-11-02)
    The primary goal of this work is to design and implement a clutch and brake system on the single tire Terramechanics rig of Advanced Vehicle Dynamics Laboratory (AVDL) at Virginia Tech. This test rig was designed and built to study the performance of tires in off-road conditions on surfaces such as soil, sand, and ice. Understanding the braking performance of tires is crucial, especially for terrains like ice, which has a low coefficient of friction. Also, rolling resistance is one of the important aspects affecting the tractive performance of a vehicle and its fuel consumption. Investigating these experimentally will help improve tire models performance. The current configuration of the test rig does not have braking and free rolling capabilities. This study involves modifications on the rig to enable free rolling testing when the clutch is disengaged and to allow braking when the clutch is engaged and the brake applied. The first part of this work involves the design and fabrication of a clutch system that would not require major changes in the setup of the test rig; this includes selecting the appropriate clutch that would meet the torque requirement, the size that would fit in the space available, and the capability to be remotely operated. The test rig's carriage has to be modified in order to fit a pneumatic clutch, its adapter, a new transmission shaft, and the mounting frame for the clutch system. The components of the actuation system consisting of pneumatic lines, the pressure regulator, valves, etc., have to be installed. Easy operation of the clutch from a remote location is enabled through the installation of a solenoid valve. The second part of this work is to design, fabricate, and install a braking system. The main task is to design a customized braking system that satisfies the various physical and functional constraints of the current configuration of the Terramechanics rig. Some other tasks are the design and fabrication of a customized rotor, selection of a suitable caliper, and design and fabrication of a customized mounting bracket for the caliper. A hydraulic actuation system is selected since it is suitable for this configuration and enables remote operation of the brakes. Finally, the rig is upgraded with the assembly of these two systems onto it.
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    Design Demonstration and Optimization of a Morphing  Aircraft Control Surface Using Flexible Matrix Composite Actuators
    Doepke, Edward Brady (Virginia Tech, 2018-03-13)
    The morphing of aircraft wings for flight control started as a necessity for the Wright Brothers but quickly fell out of favor as aircraft increased speed. Currently morphing aircraft control is one of many ideas being explored as we seek to improve aircraft efficiency, reduce noise, and other alternative aircraft solutions. The conventional hinged control surface took over as the predominant method for control due to its simplicity and allowing stiffer wings to be built. With modern technologies in variable stiffness materials, actuators, and design methods, a morphing control surface, which considers deforming a significant portion of the wing's surface continuously, can be considered. While many have considered morphing designs on the scale of small and medium size UAVs, few look at it for full-size commercial transport aircraft. One promising technology in this field is the flexible matrix composite (FMC) actuator. This muscle-like actuator can be embedded with the deformable structure and unlike many other actuators continue to actuate with the morphing of the structure. This was demonstrated in the FMC active spoiler prototype, which was a full-scale benchtop prototype, demonstrated to perform under closed-loop control for both the required deflection and load cases. Based on this FMC active spoiler concept a morphing aileron design was examined. To do this an analysis coupling the structure, fluid, and FMC actuator models was created. This allows for optimization of the design with the objectives of minimizing the hydraulic energy required and mass of the system by varying the layout of the FMC aileron, the material properties used, and the actuator's design and placement with the morphing section. Based on a commercial transport aircraft a design case was developed to investigate the optimal design of a morphing aileron using the developed analysis tool. The optimization looked at minimizing the mass and energy requirements of the morphing aileron and was subject to a series of constraints developed from the design case and the physical limitations of the system. A Pareto front was developed for these two objectives and the resulting designs along the Pareto front explored. From this optimization, a series of design guidelines were developed.