Browsing by Author "West, Robert L. Jr."

Now showing 1 - 20 of 125
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    The Abaqus/CAE Plug-in for Premium Threaded connection 3D parameter Finite Element Model
    Yan, Kaidi (Virginia Tech, 2017-06-22)
    Finite Element Analysis (FEA) is proposed to simulate the connection response of practical in-service conditions and test the performance of Oil Country Tubular Goods (OCTG) premium threaded connections. A plug-in is developed in Abaqus/CAE for creating the 360-degree full 3D parametric finite element model with helical threads as an effective design and analysis tool. All size, position and material data of the model are parameterized. The premium connection plug-in accepts input from the Graphical User Interface (GUI) for further modification. Each premium connection component is programed as a collection of single-purpose independent functions organized as an independent module in order to allow users to modify specific function behavior conveniently. A main program is designed as an Abaqus kernel plug-in to achieve all the functions by calling these independent functions, making the plug-in flexible. Each single script file is not too long to jeopardize readability. The GUI of the plug-in is designed with proper layout arrangement and illustrations to make the plug-in user-friendly and easy to use. The premium connection FE model is used in a virtual test to validate the model against the ISO 13679 test protocol and is used to develop the seal metrics for points on the ISO 13679 sealability envelope. The plug-in can be used to develop and evaluate the design envelope of the premium connection.
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    Acoustic Transfer Functions Derived from Finite Element Modeling for Thermoacoustic Stability Predictions of Gas Turbine Engines
    Black, Paul Randall (Virginia Tech, 2007-05-07)
    Acoustic Transfer Functions Derived from Finite Element Modeling for Thermoacoustic Stability Predictions of Gas Turbine Engines Design and prediction of thermoacoustic instabilities is a major challenge in aerospace propulsion and the operation of power generating gas turbine engines. This is a complex problem in which multiple physical systems couple together. Traditionally, thermoacoustic models can be reduced to dominant physics which depend only on flame dynamics and acoustics. This is the general approach adopted in this research. The primary objective of this thesis is to describe how to obtain acoustic transfer functions using finite element modeling. These acoustic transfer functions can be coupled with flame transfer functions and other dynamics to predict the thermoacoustic stability of gas turbine engines. Results of this research effort can go beyond the prediction of instability and potentially can be used as a tool in the design stage. Consequently, through the use of these modeling tools, better gas turbine engine designs can be developed, enabling expanded operating conditions and efficiencies. This thesis presents the finite element (FE) methodology used to develop the acoustic transfer functions of the Combustion System Dynamics Laboratory (CSDL) gaseous combustor to support modeling and prediction of thermoacoustic instabilities. In this research, several different areas of the acoustic modeling were addressed to develop a representative acoustics model of the hot CSDL gaseous combustor. The first area was the development and validation of the cold acoustic finite element model. A large part of this development entailed finding simple but accurate means for representing complex geometries and boundary conditions. The cold-acoustic model of the laboratory combustor was refined and validated with the experimental data taken on the combustion rig. The second stage of the research involved incorporating the flame into the FE model and has been referred to in this thesis as hot-acoustic modeling. The hot-acoustic model also required the investigation and characterization of the flame as an acoustic source. The detailed mathematical development for the full reacting acoustic wave equation was investigated and simplified sufficiently to identify the appropriate source term for the flame. It was determined that the flame could be represented in the finite element formulation as a volumetric acceleration, provided that the flame region is small compared to acoustic wavelengths. For premixed gas turbine combustor flames, this approximation of a small flame region is generally a reasonable assumption. Both the high temperature effects and the flame as an acoustic source were implemented to obtain a final hot-acoustic FE model. This model was compared to experimental data where the heat release of the flame was measured along with the acoustic quantities of pressure and velocity. Using these measurements, the hot-acoustic FE model was validated and found to correlate with the experimental data very well. The thesis concludes with a discussion of how these techniques can be utilized in large industrial-size combustors. Insights into stability are also discussed. A conclusion is then presented with the key results from this research and some suggestions for future work.
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    Analyses of Ship Collisions: Determination of Longitudinal Extent of Damage and Penetration
    Sajdak, John Anthony Waltham (Virginia Tech, 2004-07-29)
    The overall objective of this thesis is to develop, validate and assess a probabilistic collision damage model to support ongoing work by the Society of Naval Architecture and Marine Engineering (SNAME) Ad Hoc Panel #6 and IMO working groups. It is generally agreed that structural design has a major influence on tanker oil outflow and damaged stability in grounding and collision, but crashworthiness is not considered in present regulations. The proposed methodology provides a practical means of considering structural design in a regulatory framework, and when implemented would improve the safety and environmental performance of ships. This thesis continues the development and applies a Simplified Collision Model (SIMCOL) to calculate damage extent (transverse, vertical and longitudinal) and oil outflow in ship collisions. The primary contribution of this thesis is the development and validation of a theory for the determination of energy absorbed in longitudinal extent of damage, and the implementation of the theory within SIMCOL. SIMCOL is sufficiently fast to be applied to thousands of collision cases as is required for a probabilistic analysis. The following specific tasks were completed using SIMCOL in support of this project: Completed the development of SIMCOL Version 3.0 including: 1) Deformable Bow sub model 2) Implementation and validation of theory for the determination of energy absorbed in longitudinal extent of damage. • Developed the capability to model collision events using LSDYNA. • Validated Virginia Tech LSDYNA ship collision modeling procedure. • Validated SIMCOL using real collision data, and probabilistic collision data for penetrating collisions.
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    Analysis of the Dynamic Interferences Between the Stator and Rotor of a Refrigeration Compressor Motor
    Thompson, Swen (Virginia Tech, 1997-07-05)
    This thesis involves the development and study of a finite element model of a hermetic, single-vane compressor and a single-phase alternating current induction motor assembled in a common housing. The manufacturer of this unit is experiencing a high scrap rate due to interference during operation between the stator and rotor of the motor. The rotor shaft of the motor is non-typical because of its cantilever design. The finite element model was first subjected to eigenvalue analysis. This revealed that the interference producing displacements were not the result of torque application to the rotor at a frequency close to an eigenvalue of the mechanical system. After a review of the literature and discussions with Electrical Engineering Department faculty possessing extensive motor experience, it was surmised that the physical phenomenon causing the rotor displacement was unbalanced magnetic pull. This phenomenon occurs in the air gap of rotating electric machines due to eccentricity in the air gap. The model was then subjected to simultaneous harmonic force inputs with magnitudes of unity on the rotor and stator surfaces to simulate the presence of unbalanced magnetic pull. It was found that the rotor shaft acts as a cantilever beam while the stator and housing are essentially rigid. The displacements due to these forces were examined and then scaled to develop the motor parameters necessary to produce the radial forces required for stator/rotor interference. Several recommendations were then made regarding possible solutions to the interference problem.
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    An Approach to Using Finite Element Models to Predict Suspension Member Loads in a Formula SAE Vehicle
    Borg, Lane (Virginia Tech, 2009-05-28)
    A racing vehicle suspension system is a kinematic linkage that supports the vehicle under complex loading scenarios. The suspension also defines the handling characteristics of the vehicle. Understanding the loads that the suspension carries in a variety of loading scenarios is necessary in order to properly design a safe and effective suspension system. In the past, the Formula SAE team at Virginia Tech has used simplified calculations to determine the loads expected in the suspension members. This approach involves several large assumptions. These assumptions have been used for years and the justification for them has been lost. The goal of this research is to determine the validity of each of the assumptions made in the method used for calculating the vehicle suspension loads by hand. These assumptions include modeling the suspension as pinned-pinned truss members to prevent bending, neglecting any steering angle input to the suspension, and neglecting vertical articulation of the system. This thesis presents an approach to modeling the suspension member loads by creating a finite element (FE) model of the entire suspension system. The first stage of this research covers the validation of the current calculation methods. The FE model will replicate the suspension with all of the current assumptions and the member loads will be compared to the hand calculations. This truss-element-based FE model resulted in member loads identical to the hand calculations. The next stage of the FE model development converts the truss model to beam elements. This step is performed to determine if the assumption that bending loads are insignificant is a valid approach to calculating member loads. In addition to changing the elements used from truss to beam element, the suspension linkage was adapted to more accurately model the methods by which each member is attached to the others. This involves welding the members of each control arm together at the outboard point as well as creating a simplified version of the pull rod mounting bracket on the upper control arm. The pull rod is the member that connects the ride spring, damper, and anti-roll bar to the wheel assembly and had previously been mounted on the upright. This model reveals reduced axial components of load but increases in bending moments sizable enough to reduce the resistance to buckling of any member in compression. The third stage of model development incorporates the steer angle that must be present in loading scenarios that involve some level of cornering. An analysis of the vehicle trajectory that includes the effects of slip angle is presented and used to determine the most likely steer angle the vehicle will experience under cornering. The FE model was adapted to include the movement of the steering linkage caused by driver input. This movement changes the angle of the upright and steering linkage as well as the angle at which wheel loads are applied to the suspension. This model results in a dramatic change in member loads for loading cases that involve a component of steering input. Finally, the FE model was further enhanced to account for vertical movement of the suspension as allowed by the spring and damper assembly. The quasi-static loading scenarios are used to determine any member loading change due to vertical movement. The FE model is also used to predict the amount of vertical movement expected at the wheel center. This data can be used by the suspension designer to determine if changes to the spring rate or anti-roll bar stiffness will result in a more desirable amount of wheel movement for a given loading condition. This model shows that there is no change in the member loads due to the vertical movement of the wheel. This thesis concludes by presenting the most important changes that must occur in member load calculations to determine the proper suspension loading under a variety of loading scenarios. Finally, a discussion of future research is offered including the importance of each area in determining suspension loads and recommendations on how to perform this research.
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    Assessment of Thermal Behavior and Development of Thermal Design Guidelines for Integrated Power Electronics Modules
    Pang, Ying-Feng (Virginia Tech, 2005-01-20)
    With the increase dependency on electricity to provide correct form of electricity for lightning, machines, and home and office appliances, the need for the introduction of high reliability power electronics in converting the raw form of electricity into efficient electricity for these applications is uprising. One of the most common failures in power electronics is temperature related failure such as overheating. To address the issue of overheating, thermal management becomes an important mission in the design of the power electronics to ensure the functional power electronics. Different approaches are taken by academia and industry researchers to provide efficient power electronics. In particular, the Center for Power Electronics System (CPES) at Virginia Tech and four other universities presented the IPEM approach by introducing integrated power electronics modules (IPEM) as standardized units that will enable greater integration within power electronics systems and their end-use application. The IPEM approach increases the integration in the components that make up a power electronics system through novel a packaging technique known as Embedded Power technology. While the thermal behavior of commonly used packages such as pin grid arrays (PGA), ball grid array (BGA), or quad flat pack (QFP) are well-studied, the influence of the Embedded Power packaging architecture on the overall thermal performance of the IPEMs is not well known. This motivates the presentation of this dissertation in developing an in-depth understanding on the thermal behavior of the Embedded Power modules. In addition, this dissertation outlines some general guidelines for the thermal modeling and thermal testing for the Embedded Power modules. Finally, this dissertation summarizes a few thermal design guidelines for the Embedded Power modules. Hence, this dissertation aims to present significant and generalized scientific findings for the Embedded Power packaging from the thermal perspective. Both numerical and experimental approaches were used in the studies. Three-dimensional mathematical modeling and computational fluid dynamics (CFD) thermal analyses were performed using commercial numerical software, I-DEAS. Experiments were conducted to validate the numerical models, characterize the thermal performance of the Embedded Power modules, and investigate various cooling strategies for the Embedded Power modules. Validated thermal models were used for various thermal analyses including identifying potential thermal problems, recognizing critical thermal design parameters, and exploring different integrated cooling strategies. This research quantifies various thermal design parameters such as the geometrical effect and the material properties on the thermal performance of the Embedded Power modules. These parameters include the chip-to-chip distance, the copper trace area, the polyimide thickness, and the ceramic materials. Since the Embedded Power technology utilizes metallization bonding as interconnection, specific design parameters such as the interconnect via holes pattern and size, the metallization thickness, as well as the metallization materials were also explored to achieve best results based on thermal and stress analyses. With identified potential thermal problems and critical thermal design parameters, different integrated cooling strategies were studied. The concept of integrated cooling is to incorporate the cooling mechanisms into the structure of Embedded Power modules. The results showed that simple structural modifications to the current Embedded Power modules can reduce the maximum temperature of the module by as much as 24%. Further improvement can be achieved by employing double-sided cooling to the Embedded Power modules. Based on the findings from the thermal analyses, general design guidelines were developed for future design of such Embedded Power modules. In addition, thermal modeling and testing guidelines for the Embedded Power modules were also outlined in this dissertation.
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    An automated methodology for dynamic force analysis of adaptive spatial trusses
    Lacy, David Terrell (Virginia Tech, 1991-05-15)
    The purpose of this thesis is to develop a formal methodology for determining the loads occurring in the members of an adaptive truss due to both gravity and acceleration. This force analysis can be used as the basis for a design code which will provide truss member dimensions and actuator characteristics. Three different truss structures are considered. The first is a planar, triangular truss consisting of one actuated member and two fixed length members. The second structure is a spatial, double-octahedral truss with three active members and eighteen fixed length members. The third structure is a truss consisting of several double-octahedral bays connected together as a chain. For each structure, the active link motion is first simulated and the position, velocity, and acceleration history of each of the member connecting points is calculated. The dynamic equations of motion for each member are developed and combined to form a system of equations describing the motion of the entire truss. These equations are then solved to find the forces occurring at each node. Once the forces are determined, the internal forces in each member can be found, and the resulting stresses are calculated. The members are also checked for buckling using Euler buckling theory. The stress calculations are checked against experimental values and show good agreement for both static only and static and dynamic loading.
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    A Bayesian statistics approach to updating finite element models with frequency response data
    Lindholm, Brian Eric (Virginia Tech, 1996-08-05)
    This dissertation addresses the task of updating finite element models with frequency response data acquired in a structural dynamics test. Standard statistical techniques are used to generate statistically qualified data, which is then used in a Bayesian statistics regression formulation to update the finite element model. The Bayesian formulation allows the analyst to incorporate engineering judgment (in the form of prior knowledge) into the analysis and helps ensure that reasonable and realistic answers are obtained. The formulation includes true statistical weights derived from experimental data as well as a new formulation of the Bayesian regression problem that reduces the effects of numerical ill-conditioning. Model updates are performed with a simulated free-free beam, a simple steel frame, and a cantilever beam. Improved finite element models of the structures are obtained and several statistical tests are used to ensure that the models are improved.
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    Bipedal Walking for a Full Size Humanoid Robot Utilizing Sinusoidal Feet Trajectories and Its Energy Consumption
    Han, Jea-Kweon (Virginia Tech, 2012-04-24)
    This research effort aims to develop a series of full-sized humanoid robots, and to research a simple but reliable bipedal walking method. Since the debut of Wabot from Waseda University in 1973, several full-sized humanoid robots have been developed around the world that can walk, and run. Although various humanoid robots have successfully demonstrated their capabilities, bipedal walking methods are still one of the main technical challenges that robotics researchers are attempting to solve. It is still challenging because most bipedal walking methods, including ZMP (Zero Moment Point) require not only fast sensor feedback, but also fast and precise control of actuators. For this reason, only a small number of research groups have the ability to create full-sized humanoid robots that can walk and run. However, if we consider this problem from a different standpoint, the development of a full-sized humanoid robot can be simplified as long as the bipedal walking method is easily formulated. Therefore, this research focuses on developing a simple but reliable bipedal walking method. It then presents the designs of two versions of a new class of super lightweight (less than 13 kg), full-sized (taller than 1.4 m) humanoid robots called CHARLI-L (Cognitive Humanoid Autonomous Robot with Learning Intelligence – Lightweight) and CHARLI-2. These robots have unique designs compared to other full- sized humanoid robots. CHARLI-L utilizes spring assisted parallel four-bar linkages with synchronized actuation to achieve the goals of lightweight and low cost. Based on the experience and lesions learned from CHARLI-L, CHARLI-2 uses gear train reduction mechanisms, instead of parallel four-bar linkages, to increase actuation torque at the joints while further reducing weight. Both robots successfully demonstrated untethered bipedal locomotion using an intuitive walking method with sinusoidal foot movement. This walking method is based on the ZMP method. Motion capture tests using six high speed infrared cameras validate the proposed bipedal walking method. Additionally, the total power and energy consumptions during walking are calculated from measured actuator currents.
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    Characterization and Development of General Material Models for Use in Modeling Structures Bonded with Ductile Adhesives
    Cassino, Christopher (Virginia Tech, 2005-04-22)
    Structural adhesives are materials that are capable of bearing significant loads in shear, and sometimes tension, over a range of strains and strain rates. Adhesively bonded structures can dissipate large amounts of mechanical energy and can be lighter and more efficient than many bolted or vibration welded parts. The largest barrier to using structural adhesives in more applications is the many challenges engineers are presented with when designing and analyzing adhesively bonded structures. This study develops, characterizes and compares several material models for use in finite element analysis of adhesively bonded structures, in general, and a bonded tongue and groove (TNG) joint in particular. The results indicate that it is possible to develop a general material model for ductile adhesives used in structural applications under quasi-static conditions. Furthermore, the results also show that it is also possible to take bulk material data and apply it to an adhesively bonded specimen provided that the mode of failure of the bulk test specimen closely approximates the mode of failure of the bonded joint.
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    Characterization of a Pressure Sensitive Adhesive (PSA) for Mechanical Design
    Hennage, John B. (Virginia Tech, 2004-10-12)
    This thesis outlines a methodology for formatting and applying stress models, collecting visco-elastic material properties, and presenting the material data for use in adhesive joint designs. There are a number of models/theories that can be applied to the design of Pressure Sensitive Adhesive (PSA) joints. Unfortunately, few design engineers are familiar with these models and the models are not formatted in a manner that can easily be applied to joint designs. By developing a format that is based on the existing knowledge of the designer and presenting them in a familiar manner the theories/models can easily be used in joint designs. This technique was demonstrated with Beam-on-Elastic Foundation, Shear Lag, and Shape Factors. Design examples successfully demonstrated the application of all of these models in the analysis and design of simple adhesive joints. The material properties of PSAs are a function of loading/displacement rate, temperature, relative humidity, and stress state. The Arcanm fixture was used to test VHB™ 4950 over a range loading and stress states including fixed load and displacement rates. Several bond widths were tested to determine the extent of the shape factor effect. A second fixture was used to determine the impact of gradient-tensile stresses on the failure strength. All of the collected data was used to generate design plots. The strength data was presented as allowable strength envelopes with respect to rate. The moduli were calculated from the load-displacement data and plotted with respect to the displacement rate. The failure strength from the fixed load and displacement data were used to transform from one loading case to the other and a plot was generated. These three plots were used in the design and analysis of several adhesive joints. The methods demonstrated in this thesis show a great deal of promises as a design tool, but there is still a large amount of work to be done. The design space for this material is much larger than what was covered by this work. Additional strength testing needs to be conducted to fully characterize the material for all key applications. The principle of time-temperature superposition, beam-on-elastic foundation, shear lag, and shape factors all need to be validated for this material.
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    Collision Analysis of the Reversible Crankshaft Mechanism in a Convertible Refrigeration Compressor
    Cain, Jason James (Virginia Tech, 2000-06-02)
    The purpose of this study is to analyze the behavior of a reversible two-cylinder refrigerant compressor manufactured by Bristol Compressor Incorporated. This compressor contains a specialized linkage that causes the compressor to transition from a two-cylinder compressor to a single-cylinder compressor when the direction of rotation of the crankshaft is reversed. The linkage accomplishes this by reducing the throw of one cylinder to zero. Of interest are the conditions to which this linkage is subjected when the direction of rotation is again reversed, causing the compressor to return to its two-cylinder functioning. When this reversal takes place, a collision occurs within the linkage. These repeated collisions are thought to be the cause of fatigue failure of the linkage in many of these compressors. To verify that this collision is the problem, an understanding of the stress state during the collision is needed. This thesis begins the work necessary to determine the dynamic stress state present within the system. A FORTRAN program was developed that modeled the kinematic behavior of the system under operating conditions. The program predicts the accelerations, velocities, positions, and internal forces present within the system during startup conditions. Also, a method has been developed to model rotary sliding contact between two cylindrical surfaces. This method is developed and investigated in hopes that it will facilitate the modeling of the behavior of the compressor linkage in a dynamic finite element analysis.
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    Comparing In Situ and Bulk Constitutive Properties of a Structural Adhesive
    Grohs, Joshua Walter (Virginia Tech, 2007-07-20)
    In the continuing quest for more efficient designs, structural adhesives are being used in place of, or with, traditional fastening methods; however designing with adhesives is refined as traditional methods. To obtain the adhesive design properties, tests are often performed on bulk tensile and bonded shear specimens. Questions remain about the relationship between properties obtained from in situ adhesive joints and bulk adhesive specimens. As a result, an experimental plan was developed which characterized both the linear and nonlinear region of bulk and in situ adhesive performance of a two-part acrylic adhesive from Dow Chemical Company. A standard uniaxial tensile test was used for the bulk normal, while an Iosipescu shear test was used to characterize the bulk shear performance. In situ testing was performed on a napkin-ring specimen loaded in both tension and torsion. Stress-strain relationships in both shear and normal were developed and bulk and in situ adhesive performance was compared. Observations from testing were: 1. Bulk shear and in situ shear tests showed similar performance in both the linear and nonlinear regions. 2. Modulus of elasticity in bulk adhesive tests was similar to the effective modulus of elasticity in in situ tests. 3. Prediction of normal yield strengths of the in situ adhesive through simple failure theory models proved to be inaccurate. Stress singularities, loading imperfections, and potentially a hydrostatic sensitivity were considered possible explanations. 4. Adhesive showed sensitivity to voiding and surface flaws when loaded in a tensile configuration, refinement of specimen fabrication minimized these effects.
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    Complex Bogie Modeling Incorporating Advanced Friction Wedge Components
    Sperry, Brian James (Virginia Tech, 2009-05-11)
    The design of the freight train truck has gone relatively unchanged over the past 150 years. There has been relatively little change to the fundamental railway truck design because of the challenges of implementing a cost effective and reliable modification to designs that have proven effective in decades of operation. A common U. S. railway truck consists of two sideframes, a bolster, two spring nests, and four friction wedges. The two sideframes sit on the axels. The bolster rides on springs on top of the sideframes. The friction wedges also ride on springs on top of the sideframe, and are positioned between the bolster and sideframe, acting as a damping mechanism. Better understanding the dynamic behavior and forces on the bodies are critical in reducing unnecessary wear on the components, along with potential negative behavior such as loss of productivity and increase in operating costs. This thesis will investigate the dynamic behavior of the truck under warping conditions using a stand-alone model created in Virtual.Lab. This research covers two main areas. First, the full-truck model will be developed and its simulation results will be compared to test data from the Transportation Technology Center, Inc. (TTCI). Data was provided from warp testing performed at the TTCI facilities in the spring of 2008. Once validated, the model will be used to gain a better understanding of the forces and moments that are propagated through the system, and of the dynamics of all bodies. Due to costs and physical constraints, not every bogie component can be instrumented during test, so the computer model will be able to provide valuable information not easily obtained otherwise. Second, full-truck models using different contact geometry between the wedges, sideframes, and bolster will be compared. A model with extremely worn sideframes will allow for investigation into the effects of wear on the damping abilities and warp stiffness of the truck. Another model using split wedges will be compared with the previous model to investigate into the behavior differences in the truck using different types of wedges. By understanding the impact of different geometries on the overall performance of the truck, better decisions on design and maintenance can be made in the future. After creating the models, we found that the full-truck model created in LMS® Virtual.Lab compared well with the test data collected by TTCI. In the comparison with NUCARS® we determined that the stand-alone model, which incorporates the wedges as bodies, captures the warp dynamics of the truck better than NUCARS®, which models the wedges as connections. By creating a model with severely worn sideframes, we were able to determine that the truck loses its abilities to damp bounce in the system as well as to prevent warping when the components become sufficiently worn. The split-wedge model behaved similarly to the standard full-truck model for bounce inputs, but had a significantly different behavior in warp. Further development will be needed on the split-wedge model to be confident that it behaved as expected.
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    Compression Failure of Aluminum Plates Exposed to Constant Heat Flux
    Fogle, Emily Johanna (Virginia Tech, 2010-05-05)
    Aluminum is used as a structural member in marine applications because of its low weight. One challenge is to design against failure of aluminum structures in fire. A parametric study was performed to quantify the effects of parameters on the compression failure of aluminum plates during a fire. A thermo-structural apparatus was designed to perform compression tests on aluminum samples consisting of a compression load frame, a hydraulic system, and electric heaters. The effect of dimensional variation on failure behavior was examined. Aluminum 5083 and 6082 alloys were tested with three thicknesses, two lengths and two widths. Three heat fluxes and various buckling stresses were used. Micro Vicker's hardness values were measured before and after testing to quantify the effect of heating on the strength of the aluminum. In general, lower applied stress resulted in higher failure temperature and longer time to failure. Dimensional variations had a negligible effect on failure behavior. The 5083 alloy has a minimum stress level of 50% of the buckling stress at 10kW/m2 and 10% of the buckling stress at 20kW/m2, while the 6082 alloy has a minimum stress level of 75% of the buckling stress at 10kW/m2 and 25% of the buckling stress at 20kW/m2. The 6082 failed at higher temperatures and longer failure times than the 5083. The presence of insulation on the exposed surface decreased the temperature rise, resulting in longer failure times. Vicker's hardness decreased with heating in general. The results describe the effects of parameters of the failure of aluminum.
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    Computational Fluid Dynamic and Rotordynamic Study on the Labyrinth Seal
    Gao, Rui (Virginia Tech, 2012-06-14)
    The labyrinth seal is widely used in turbo machines to reduce leakage flow. The stability of the rotor is influenced by the labyrinth seal because of the driving forces generated in the seal. The working fluid usually has a circumferential velocity component before entering the seal; the ratio of circumferential velocity and shaft synchronous surface velocity is defined as pre-swirl rate. It has been observed that pre-swirl rate is an important factor affecting driving forces in the labyrinth seal thus affecting the stability of the rotor. Besides the pre-swirl, the eccentricity, the clearance, and the configuration of tooth locations are all factors affecting the rotordynamic properties of the labyrinth seal. So it is of interest to investigate the exact relationships between those factors and the seal's rotordynamic properties. In this research, three types of labyrinth seals have been modeled: the straight eye seal, the stepped eye seal, and the balance drum seal. For the straight eye seal, a series of models were built to study the influence of eccentricity and clearance. The other two seals each have only one model. All models were built with Solid Works and meshed with ANSYS-ICEM. Flows in those models were simulated by numerically solving the Reynolds-Averaged Navier-Stokes (RANS) equations in the ANSYS-CFX and then rotordynamic coefficients for each seal were calculated based on the numerical results. It had previously been very difficult to generate a pre-swirl rate higher than 60% in a numerical simulation. So three ways to create pre-swirl in ANSYS-CFX were studied and finally the method by specifying the inlet velocity ratio was employed. Numerical methods used in this research were introduced including the frame transfer, the k-ε turbulence model with curvature correction, and the scalable wall function. To obtain the optimal mesh and minimize the discretization error, a systematical grid study was conducted including grid independence studies and discretization error estimations. Some of the results were compared with previous bulk-flow or experimental results to validate the numerical model and method. The fluid field in the labyrinth seal must be analyzed before conducting rotordynamic analysis. The predicted pressure distributions and leakages were compared with bulk-flow results. A second small vortex at the downstream edge of each tooth was found in the straight eye seal. This has never been reported before and the discovery of this small vortex will help to improve seal designs in the future. The detailed flows in discharged region and in chambers were also discussed. Radial and tangential forces on the rotor were solved based on the fluid field results. It is shown that the traditional first-order rotordynamic model works well for low pre-swirl cases but does not accurately reflect the characteristics for high pre-swirl cases. For example compressor eye seals usually have pre-swirl rates bigger than 70% and the second order model is required. Thus a second-order model including inertia terms was built and applied to the rotordynamic analysis in this research. The influence of pre-swirl, eccentricity and clearance were studied using the straight eye seal model. The rotordynamic characteristics of the stepped eye seal and the balance drum seal were studied considering high pre-swirl rates. Some relationships between influencing factors and the four rotordynamic coefficients were concluded. The results also showed that for all the three seals higher pre-swirl leads to higher cross-coupled stiffness which is one of the main factors causing rotor instability. The rotor stability analysis was conducted to study the influence of drum balance seal on the stability. The rotor was designed with typical dimensions and natural frequencies for a centrifugal compressor rotor. The parameters for bearing and aerodynamic force were also set according to general case in compressors to minimize the effects from them. The result shows that the high pre-swirl rate in balance drum seal leads to rotor instability, which confirmed the significant effect of pre-swirl on the seal and the rotor system.
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    A Computational Fluid Dynamics Investigation of Thermoacoustic Instabilities in Premixed Laminar and Turbulent Combustion Systems
    Chatterjee, Prateep (Virginia Tech, 2004-07-06)
    Lean premixed combustors have been designed to lower NOx and other pollutant levels in land based gas turbines. These combustors are often susceptible to thermo-acoustic instabilities, which manifest as pressure and heat release oscillations in the combustor. To be able to predict and control these instabilities, it is required that both the acoustics of the system, and a frequency-resolved response of the combustion process to incoming perturbations be understood. Currently, a system-level approach is being used widely to predict the thermoacoustic instabilities. This approach requires simple, yet accurate models which would describe the behavior of each dynamic block within the loop. The present study is directed toward using computational fluid dynamics (CFD) as a tool in developing reduced order models for the dynamics of laminar flat flames and swirl stabilized turbulent flames. A finite-volume based approach is being used to simulate reacting flows in both laminar and turbulent combustors. The study has been divided into three parts -- the first part involves the modeling of a self-excited combustor (the acoustics of the combustor are coupled with the unsteady heat release); the second part of the research aims to study the effect of velocity perturbations on the unsteady heat release rate from a burner stabilized laminar flat flame; the third and final part of work involves an extension of the laminar flat flame study to turbulent reacting flows in a swirl stabilized combustor, and study the effects on the turbulent heat release due to the velocity perturbations. A Rijke tube combustor was selected to study self-excited combustion phenomenon. A laminar premixed methane-air flat flame was stabilized on a honeycomb flame-stabilizer. The flame stabilizer was placed at the center of the 5 feet vertical tube. The position of the flame at the center of the tube leads to a thermoacoustic instability of the 2nd acoustic mode. The fundamental thermoacoustic frequency was predicted accurately by the CFD model and the amplitude was reasonably matched (for a flow rate of Q = 120 cc/s and equivalence ratio phi = 1.0). Other characteristics of the pressure power spectrum were captured to a good degree of accuracy. This included the amplitude modulation of the fundamental and the harmonics due to a subsonic pulsating instability. The flat flame study has been being conducted for Q = 200 cc/s and equivalence ratio phi = 0.75. The objective has been to obtain a frequency response function (FRF) of the unsteady heat release rate (output) due to incoming velocity perturbations (input). A range of frequencies (15 Hz - 500 Hz) have been selected for generating the FRF. The aim of this part of the study has been to validate the computational model against the experimental results and propose a physics based interpretation of the flame response. Detailed heat transfer modeling (including radiation heat transfer) and two-step chemistry models have been implemented in the model. The FRF generated has been able to reproduce the experimentally observed phenomena, like the low frequency pulsating instability occurring at 30 Hz. A heat transfer study has been conducted to explain the pulsating instability and a fuel variability study has been performed. Both the heat transfer study and the fuel variability study proved the role of heat transfer in creating the pulsating instability. The final part of the study involves simulation of reacting flow in a turbulent swirl stabilized combustor. The effect of velocity perturbations on the unsteady heat release has been studied by creating an FRF between the unsteady velocity and the unsteady heat release rate. A Large Eddy Simulation (LES) approach has been selected. A swirl number of S = 1.19 corresponding to a flow rate of Q = 20 SCFM with an equivalence ratio of phi = 0.75 have been implemented. Reduced reaction chemistry modeling, turbulence-chemistry interaction and heat transfer modeling have been incorporated in the model. The LES of reacting flow has shown vortex-flame interaction occurring inside the combustor. This interaction has been shown to occur at 255 Hz. The FRF obtained between unsteady velocity and unsteady heat release rate shows good comparison with the experimentally obtained FRF.
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    Computational Investigations of Boundary Condition Effects on Simulations of  Thermoacoustic Instabilities
    Wang, Qingzhao (Virginia Tech, 2016-02-17)
    This dissertation presents a formulation of the Continuous Sensitivity Equation Method (CSEM) applied to the Computational Fluid Dynamics (CFD) simulation of thermoacoustic instability problems. The proposed sensitivity analysis approach only requires a single run of the CFD simulation. Moreover, the sensitivities of field variables, pressure, velocity and temperature to boundary-condition parameters are directly obtained from the solution to sensitivity equations. Thermoacoustic instability is predicted by the Rayleigh criterion. The sensitivity of the Rayleigh index is computed utilizing the sensitivities of field variables. The application of the CSEM to thermoacoustic instability problems is demonstrated by two classic examples. The first example explores the effects of the heated wall temperature on the one-dimensional thermoacoustic convection. The sensitivity of the Rayleigh index, which is the indicator of thermoacoustic instabilities, is computed by the sensitivity of field variables. As the heat wall temperature increases, the sensitivity of the Rayleigh index decreases. The evolution from positive to negative sensitivity values suggests the transition from a destabilizing trend to stabilizing trend of the thermoacoustic system. Thermoacoustic instabilities in a self-excited Rijke tube are investigated following the relatively simple thermoacoustic convection problem. The complexity of simulating the Rijke tube increases in both dimensions and mechanisms which incorporate the species transport process and chemical reactions. As a representative model of the large lean premixed combustor, Rijke tube has been extensively studied. Quantitative sensitivity analysis sets the present work apart from previous research on the prediction and control of thermoacoustic instabilities. The effects of two boundary-condition parameters, i.e. the inlet mass flow rate and the equivalence ratio, are tested respectively. Small variations in both parameters predict a rapid change in sensitivities of field variables in the early stage of the total time length of 1.2s. The sensitivity of the Rayleigh index "blows up" at a specific time point of the early stage. In addition, variations in the inlet mass flow rate and the equivalence ratio lead to opposite effects on the sensitivity of the Rayleigh index. There exist some common findings on the application of the CSEM. For both thermoacoustic problems, the sensitivities of field variables and the Rayleigh index exhibit oscillatory nature, confirming that thermoacoustic instability is an overall effect of the coupling process between fluctuations of pressure and heat release rate. All the sensitivities of the Rayleigh index show rapid changes and "blow up" in the early stage. Although the numerical errors could influence the fidelity of computational results, it is believed that the rapid changes reflect the susceptibility to thermoacoustic instabilities in the studied systems. It should also be noted that the sensitivities are obtained for small variations in influential parameters. Therefore, the resulting sensitivities do not predict the occurrence of thermoacoustic instabilities under a condition that is far from the reference state determined by either CFD simulation results (employed in this dissertation) or experimental data. The sensitivity solver developed for the present research has the feature of flexibility. Additional mechanisms and more complicated instability criteria could be easily incorporated into the solver. Moreover, the sensitivity equations formulated in this dissertation are derived from the full set of nonlinear governing equations. Therefore, it is possible to extend the use of the sensitivity solver to other CFD problems. The developed sensitivity solver needs to be optimized to gain better performance, which is considered to be the primary future work of this research.
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    Computational Methods for Estimating Rail Life
    Holland, Chase Carlton (Virginia Tech, 2012-02-20)
    In American rail operations, rails fail due to the combined effects of rail wear due to repetitive wheel contact and the growth of surface and sub-surface cracks and flaws. Rail maintenance includes frequent uncoupled wear and ultrasonic inspections that determine the amount of wear that the rail has undergone and the presence of cracks and flaws. A rail is removed from service when its wear reaches a pre-determined wear limit or a flaw is detected in its cross section. In rail research, the life of a rail is typically estimated using fracture mechanic or fatigue methods and an assumed flaw geometry. Multiple models ranging from complex elastic-plastic finite element models to simplified representations of a beam on an elastic foundation have been developed to predict the life of a rail. The majority of rail failure models do not incorporate rail wear into their analysis, and assume an unworn rail geometry. In order to account for rail wear, certain models adopt simplified rail geometries that uncouple rail wear into top-wear and side-wear. This thesis presents a rail failure model that describes the combined effects of rail wear and crack growth through the development of a functional relationship between input variables describing the geometry, loading, and material properties of a given rail and output variables describing the life characteristics of the rail. This relationship takes the form of multiple response surfaces estimating the desired output variables. Finite element models incorporating worn rail profiles and an assumed crack geometry corresponding to a detail fracture are combined to determine the state of stress and strain at the assumed flaw. Strain-life fatigue methods and fracture mechanic concepts are used to develop the output variables necessary to describe the life of the rail using the finite element model results. The goals of this research are to predict the remaining fatigue life and estimate the crack-growth rate of the rail based on the minimum number of geometry, loading, and material property independent variables. The outputs developed to describe the rail's remaining life are intended to be used for the decision making for rail removal.
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    A Computational Study into the Effect of Structure and Orientation of the Red Ear Slider Turtle Utricle on Hair Bundle Stimulus
    Davis, Julian Ly (Virginia Tech, 2007-11-30)
    The vestibular system consists of several organs that contribute to ones sense of balance. One set of organs, otoconial organs, have been shown to respond to linear acceleration (1949). Hair bundles (and hair cells), which are the mechano-electric transducers found within otoconial organs, respond to displacement of the overlying otoconial membrane (OM). Structure, position and orientation of the OM within the head may influence the stimulus of hair bundles by changing the deformation characteristics of the OM. Therefore, studying the deformation characteristics of the OM with finite element models presents a unique advantage: the ability to study how different variables may influence the deformation of the OM. Previous OM models have ignored complicated OM geometry in favor of single degree of freedom (De Vries 1951)or distributed parameter models (Grant et al. 1984; Grant and Cotton 1990; Grant et al. 1994). Additionally, OMs have been modeled considering three dimensional geometry (Benser et al. 1993; Kondrachuk 2000; 2001a), however OM layer thicknesses were assumed to be constant. Further, little research has investigated the effect of position and orientation of otoconial organs on the deformation of the OM (Curthoys et al. 1999), due to natural movement of the head. The effect of structure, position and orientation of the utricle of a red ear slider turtle on the stimulation of hair bundles in the OM is investigated here. Using confocal images, a finite element model of the utricle OM is constructed considering its full 3D geometry and varying OM layer thickness. How specific geometric variables, which are missing from other OM models, effect the deformation of the utricle OM is studied. Next, since hair bundles are part of the structure of the OM, their contribution to the deformation of the utricular OM is quantified. Then, using computed tomography of a turtle head and high speed video of turtle feeding strikes, acceleration at the utricle during natural motion is estimated. Finally, the effects of orientation of the utricle in the head on the stimulus of hair bundles within the organ is investigated. In summary, a model and methods are developed through which deformation of the turtle utricle OM through natural movements of the head may be studied. Variables that may contribute to utricle OM deformation are investigated. Utricle OM geometry, hair bundles, position and orientation all play a role in utricle OM deflection and therefore hair bundle stimulus. Their effects are quantified and their roles are discussed in this dissertation.