Robotic ultrasonic welding monitored in realtime with a force sensor and infrared thermal imaging camera is developed as an instructional project and laboratory component for undergraduate engineering education. The broad aim is to integrate robotics, plastic component manufacture, and thermal imaging with a unified theme. A secondary aim is to adapt ultrasonic welding for rapid prototyping as a tool for student design projects. Plastic parts for microsystems, such as lab-on-a-chip devices, made by laser cutting or 3d printing, are ultrasonically welded and tensile-stress tested and leaked checked.

Sudden concrete failure is due to inelastic deformations of concrete subjected to tension. However, synthesizing nanomaterials reinforcements has significant impact on cement-based composites failure mechanism. Nanomaterials morphology bridges cement crystals as homogeneous and ductile matrix. In this experiment, cement matrix with water to cement ratio of 0.5 reinforced by 0.2–0.6 wt% of functionalized (COOH group) multi-walled and single-walled carbon nanotubes were used. After sonication of carbon nanotubes in water solution for an hour, the cementitious nanocomposites were casted in cylindrical molds (25 mm diameter and 50 mm height). Failure mechanism of cementitious nanocomposite showed considerable ductility throughout splitting tensile test compared to cement mortar. Additionally, the failure pattern after developing the initial crack provided additional time before ultimate failure occurred in cement-based nanocomposites. The evolution of crack propagation was assessed until ultimate specimen failure during splitting-tensile test on cementitious nanocomposite surface. The deformation of cross section from circle to oval shape augmented tensile strength by 50% in cementitious nanocomposite compared to conventional cement mortar.

Robust design and analysis of carbon fiber reinforced polymers (CFRP) mandates a thorough understanding of the onset and propagation of damaging mechanisms. Damage can manifest from fiber tension, fiber compression, matrix tension, and matrix compression. Of these damage forms, matrix compression has seen the least attention. Previous work has developed experimental specimens that enabled characterization of the onset and propagation of matrix compression damage. However, if high performance composite materials are used complications can arise when the matrix compression strength (σ MC ) exceeds the matrix tension strength (σ MT ). When the σ MC /σ MT ratio is greater than 2, compact compression (CC) specimens can exhibit matrix tension damage before the onset of matrix compression damage. The onset of matrix tension damage prevents proper characterization of matrix compression damage mechanisms. This paper presents the development of a novel stepped compact compression specimen. The reduced thickness of the stepped region allows significant matrix-compression damage to occur prior to tensile failure. Specimens comprised of 90° plies were fabricated using either a machined taper or a layering process. Both methods were successful however variability in machining generated substantial inconsistency and layering was found to be superior.

Numerical models were conducted to study the load/momentum/energy transfer to the clay and the clay response when it was used as backing behind hard and soft armor during ballistic experiments. Tie-break contacts were used to explicitly model the delamination in the composite panels. Yarn level models accounting for woven structures were used to model the soft armor. A rate-dependent material model with different responses under compression and tension, developed previously from impact tests, was used to model the clay. The clay indent depth was correlated to the momentum and kinetic energy transferred to the clay for with and without soft armor between the hard armor and clay backing.

Composite materials are becoming increasingly common in the aerospace industry. In order for simulation and modeling to accurately predict failure of composites, a material model based on observed damage mechanisms is required. Composites are commonly classified into four damage categories based on the composite constituents and their loading condition: fiber tension, fiber compression, matrix tension, and matrix compression. Previous work identified a compact compression (CC) specimen as a suitable option for isolating matrix compression damage. However upon continued testing, stable crack propagation in the specimen was limited to a relatively low material failure ratio ( σ Compressive /σ Tension ). This paper presents specimen geometry that can isolate matrix compression damage in materials with a failure ratio greater than two, the limit of the compact compression specimens. Initial specimen selection used the compact compression specimens from previous research and added additional specimens based on commonly used compressions specimens for different materials. The added specimens included center notched compression (CNC), edge notch compression (ENC), and four-point bending (4PB). All specimens were evaluated experimentally with the success criteria of controlled propagation of a matrix compression crack. In addition to propagating a controlled matrix compression crack, specimens were required to have a visible region around the stress concentrator to allow for digital image correlation (DIC) image capture during the experiments. The specimens were manufactured from a carbon fiber reinforced polymer (CFRP) with a failure ratio greater than six. CC and 4PB specimens were unable to produce a compression crack before any other failure methods were present. CNC specimens produced an unstable compression crack that progressed from the notch to the edge of the specimen too rapidly to acquire meaningful crack propagation data. ENC specimens showed some ability to stably propagate a crack, however some tests resulted in an unstable crack propagation similar to the CNC specimens. In order to increase the test repeatability, a tapered thickness was added to the specimen around the notch tip. The resulting tapered ENC (TENC) produced repeatable controlled matrix compression crack propagation. Ultimately, the specimen fails when the crack has propagated through the entire width of the specimen. TENC specimens show promise for isolating matrix compression damage in materials with high failure ratios. Continued testing of CFRP with TENC specimens could be used to refine the material model for finite element analysis.

Aluminium based metal matrix composites (MMCs) have received considerable attention in the last decade for its potential industrial applications. One of the challenges encountered using Aluminium based MMCs is understanding the influence of the reinforcement particles on the corrosion resistance and mechanical properties. In this study the corrosion behaviour and mechanical properties of Al6063 reinforced with egg shell ash and rice husk ash were investigated. Waste Egg Shell Ash (ESA) and Rice Husk Ash (RHA) 212 μm in size were used to produce the composites with 10 wt% of reinforcements via stir casting technique. The RHA and ESA were added in the ratios of 10:0, 7.5:2.5, 5:5, 2.5:7.5, 0:10. Unreinforced Al6063 was used as baseline material. Immersion tests, potentiodynamic polarization techniques, tensile tests, optical microscopy (OM) and scanning electron microscopy (SEM) were used to characterize the composites. The results showed that reinforcing with 7.5 wt% RHA + 2.5 wt% ESA provided the highest resistance to corrosion. Generally, a reduction in the corrosion rates were observed for the reinforced composites as the wt% of RHA increased. Porosity levels of the composites reduced with an increase in the percentage of ESA in the matrix. Microstructural characterization using SEM and OM revealed a distribution of pits on the composite surfaces which was more severe with increasing RHA percentage. The UTS (ultimate tensile stress) results revealed that the composite containing 10 wt% RHA had the maximum value of 161 MPa. The results demonstrate that rice husk ash and eggshell ash can be useful in producing low cost Aluminium composites with improved corrosion resistance and tensile properties.

The low carbon, nitrogen enhanced SS 304 L(N) stainless steels are one of the most potential candidates for the structural members in chemical industries and powerplants operating at hostile environments of temperature and corrosion. In service, the structural members fabricated using welding process, when subjected to a combination of mechanical load and elevated temperature can fail by fatigue. The Welding of Austenitic stainless steels using Tungsten Inert gas (TIG) is often limited by the depth of weld penetration, which can be achieved during a single pass. This necessitates for the use of multiple passes resulting in weld distortion and generation of residual stress. The Use of an electronegative flux (Activating flux) during the TIG welding (A-TIG) is known to enhance the weld penetration, thereby reducing the number of passes. The present study evaluates the fatigue crack growth in stainless steel weldment (304L(N) welds) joined using conventional Multipass TIG welding and Activated flux TIG welding at 673K. Compact Tension (C(T)) specimens having a width of 50.8 mm and a thickness of 4 mm were extracted from the location of heat-affected zone (HAZ) and weld metal (WM) for A-TIG and MP-TIG configurations. From the micro-structural evaluation of A-TIG welds, it is noted that high heat input in a single pass has favored the formation of coarse equiaxed grains along the weld center. The use of multiple passes at reduced heat input has resulted in the formation of finer grains, with the orientation of grains changing along each weld pass interface. This finer randomly oriented grains has resulted in increasing crack path resistance through the MP-TIG welds compared to A-TIG welds. Thus from a view point of fatigue crack growth, due to the presence of fine grains, conventional Multi-pass weld is superior compared to A-TIG, but in cases where there is a creep or creep-fatigue combination, the A-TIG weld may prove to be useful.

Healing technology for metallic materials is an important subject in terms of long-term reliability and durability of structural members, a healing technology to heal fatigue crack by applying heat treatment at annealing temperature level has been discovered. In this study, the influences of plasticity-induced crack closure on healing were evaluated by obtaining the crack opening load during the pre-crack introduction and evaluating the fatigue crack propagation characteristics before and after the healing heat treatment, using compact tension specimens made of carbon steel with different test conditions. As a result, the specimen with high crack opening load showed high healing effect and were able to heal up to 95% of the pre-crack length. This suggested that the residual compressive stress due to the plasticity-induced crack closure accelerates the solid-state diffusion bonding during the crack healing process and this leads to the improvement of the healing effect.

The effect of the pre-bending operation on ductility can be significant in determining the limit strains of the final product. The strain path experienced in straight tube bulging is significantly different from that of elbow (tube with pre-bending), leading to a reduction in bulge height. The Tube bending introduces strain gradient both along the tube and across the tube. In this work the effect of pre-bending on limit strains during tube bulging process is predicted — and the results are compared to the limit strains of bulged tubes without pre-bending. The Finite Element (FE) model of the bending operation is developed which utilizes an explicit dynamic finite element formulation. The PAMSTAMP 2G code is used to perform the numerical pre-bend (and bulging) simulations. Tension side of bend tube axial strain is found to be positive and hoop strain as negative and vice versa along the compression side. During the bulging, the neck usually develops perpendicular to major strain direction. During bend tube bulge test with fixed expansion and axial feed expansion of bend tubes, in both cases the crack is found to be in the axial direction.

This paper presents a novel design methodology, which combines topology and shape optimization to define material distribution in the structural design of a truss. Firstly, in order to identify the best layout, the topology optimization process in the design domain is carried out by applying the BESO (Bidirectional Evolutionary Structural Optimization) method. In this approach, the low energy elements are eliminated from an initial mesh, and a new geometry is constructed. This new geometry consists of a set of elements with a higher elastic energy. This results in a new division of material providing different zones, some subjected to higher stress and others containing less elastic energy. Moreover, the elements of the final mesh are re-arranged and modified, considering the distribution of tension. This new arrangement is constructed by aligning and rotating the original mesh elements coherently to the principal directions. In the Shape Optimization stage, the resulting TO (Topology Optimization) geometry is refined. A process of replacing the tabular mesh is performed by rearranging the remaining elements. The vertices of the mesh are set as control polygon vertices and used as reference to define the NURBS (Non-Uniform Rational B-Spline) curves. This provides a parametric representation of the boundaries, outlining the high elastic energy zones. The final stage is the optimization of the continuous and analytically defined NURBS curve outlining the solid material domain. The Shape Optimization is carried out applying a gradient-based optimization method.

Compliant mechanisms are highly preferred in applications demanding motion with high precision. These mechanisms provide friction-less, backlash-free precise motion obtained through deformation of flexible members. The double parallelogram compliant mechanism (DPCM) is one the most important compliant mechanisms to obtain highly precise straight-line motion. DPCM when operated in horizontal plane yield high precision straight-line motion (even with large deformations) useful in several engineering applications. However, constraints such as space, dead loads, etc. may demand DPCMs to be used in the vertical plane. For DPCMs operating in a vertical plane, the axial load due to gravity causes tension and compression in flexible beams which get coupled to bending under large deformations. This ultimately affects the parasitic error of straight-line motion. This paper presents a coupled analysis, along with experimental validation, of DPCM operating in vertical plane considering gravity effects with large deformation.

To support the design of a mechanism with two opposing, underactuated, multi-segmented feet that enables a small UAV to grasp and perch upon a branch or similar structure, a hybrid empirical-computational model has been developed that can be used to predict whether the mechanism can kinematically grasp structures with a range of cross-section shapes and sizes in various orientations and to quantify the forces exerted by the grasp. The model, based on experimentally-determined parameters, relates the curvature of the feet to the displacement and tension of the cable tendon which is related in turn to the weight of the UAV. The working principle of the landing gear follows the anatomy of birds that grasp and perch as tendons in their legs and feet are tensioned. Results demonstrate how the model can be used to simulate and evaluate grasping in order to determine the size and weight of a UAV for landing and perching upon a range of target structures.

This research is intended to create a prototype to generate controllable finger movement of a robotic prosthetic hand using Electromyography (EMG) signals. The instrumentation used in this project includes a Bitalino bio-signal sensor kit, skin electrodes, Arduino Uno microcontroller and a prosthetic hand. The Bitalino’s primary function is to serve as a means to obtain the EMG signal. The Arduino Uno’s function is to implement the control algorithm and actuate the robotic hand to move as intended. Using an EMG signal based counter, the method of control deemed fairly reliable since there was proportional control over the hand but it was based on the duration of the muscle in tension rather than how tense the muscle was. The overall control of the hand was generally responsive to the biological signal.

In this research, sensitivity analysis of upper and lower end angles in addition to the midpoint displacement of the flexible marine riser with respect to structural parameters such as: uniform mass per unit length, external diameter and the tension of the riser are conducted. Harsh environmental circumstances of ocean flow in addition to exerted tension on top of risers may lead to irreparable damages, so it is important to have a parametric study of dynamic response before it is controlled. The “Sobol” method is applied here as a reliable statistical method to sensitivity analysis of a flexible system. Motion equation of the system is developed based on Hamilton’s principle. The riser is modeled as a distributed parameter system. Moreover, simulations are carried out based on Assumed Mode Method (AMM) to solve PDE of the riser through mode shapes and generalized coordinates. Finally, the results of sensitivity analysis are presented.

Filmwise condensation of a low surface tension fluid (i.e. refrigerant) on microstructured aluminum surfaces is studied to investigate the effect of the structures on condensation heat transfer at low temperature. The hypothesis is that the structures may cause thinning of the condensate film at micro-scales, thus resulting in an enhancement of condensation heat transfer. However, the structures may also decrease the mobility of the condensate near the surface due to increased friction, thus potentially leading to performance deterioration. The aim of this work is to investigate which of the two counteracting mechanisms dominate during filmwise condensation. Condensation experiments are carried out in a low-temperature vacuum chamber. Compared with the Nusselt model of condensation, the microstructured surfaces, either coated or uncoated, show similar performance, with potentially slight enhancement at low subcooling degree and slight deterioration at high subcooling degree. When the microstructured and silane-coated surface is infused with a non-volatile and very low-surface-tension lubricant oil, the lubricant is displaced by the condensate and there is almost no change in the condensation performance. Our results show that, unlike the case of dropwise condensation of high-surface tension fluids, microstructured and coated surfaces with/without infusing oil is not exciting to enhanced filmwise condensation of low-surface-tension fluids.

Transverse nanoindentation modulus of high performance Kevlar KM2 single fibers are experimentally studied using a nanoindenter. Researchers have investigated the transverse compression behavior of these fibers using flat punch indentation heads, in which the curved circular transverse shape of the fiber is not included, and consecutively fit the data into the analytical models to calculate their mechanical properties. During this process, the force is normalized to a point on the transverse fiber surface and the analytical model assumes a flat semi-infinite plate for substrate. Other studies consider embedding the fibers on a substrate and indenting on the transverse surface. This method bounds the fibers resulting in inaccurate measurements of their mechanical responses. There has not been an appropriate study on the transverse material properties of the Kevlar fibers determined via nanoindentation without embedding them because it is challenging to rigidly secure the fibers. Here, we have developed a methodology to secure the Kevlar fiber on an SEM puck under pretension. The tension at the fiber is calculated and accounted for in the final determination of the mechanical properties. Fibers are glued at the ends and are not embedded. The employed Vantage nanoimpactor indents the fiber radially at three different loads, namely, 2, 3, and 5 mN and calculates the mechanical properties. A Berkovich indenter is used for indentation. The Kevlar fibers are assumed transversely isotropic and have 12μm diameter measured via the Vantage optical microscope. For Kevlar KM2 fiber the experimental transverse modulus using impact nanoindenter instrument is ∼3.46 GPa. The presented experiments aim to improve our understanding of the mechanical properties of these high performance fibers on the transverse direction.

Rapid prototyping has led to strides in improved mechanical part design flexibility and manufacturing time. Along with these advances, however, is the extremely high costs associated with additively manufacturing components that can limit a comprehensive understanding of the mechanical performance of these materials. This can be circumvented through the use of constitutive models which can both support experimental findings in addition to providing approximations of expected material behavior. The present study has demonstrated the influence of build orientation on as-built direct metal laser sintered (DMLS) stainless steel (SS) GP1/17-4PH, manufactured along varying orientations in the xy build plane, through strain-controlled tension and completely reversed low cycle fatigue experiments. Experimental findings from monotonic tension testing are used to model failure surfaces, which can be used to approximate failure regions for DMLS SS GP1 manufactured along varying build orientations within the horizontal xy build plane. Further, a Chaboche model is used to simulate the cyclic response of this material based upon experimental findings through low cycle fatigue testing. Conclusive findings from these models are used to assess the vital role that build orientation plays in affecting the mechanical performance of additively manufactured materials.

In this work, a new model of a recumbent bike with the tensegrity method is developed, where all elements in tension are substituted for steel cables, to improve the weight of the vehicle and to absorb some of the impacts of the tires, since the cable works as a shock absorber. The aim of this study is to determine the structural strength of each of the elements of the recumbent vehicle and to establish dimensions and construction materials. The model is divided in 6 different elements, applying the equivalent loads and constrains to simulate the interaction with other elements, the user and the road, based on the HPVC 2017 rules [1]. Results show that in the analyzed sections, the maximum Von Mises stress obtained for all elements is 116 MPa, obtaining a minimum safety factor of 2.37 against tensile yield strength. Finally, through this work it is possible to apply the finite element method for failure analysis of each of the components of a recumbent vehicle and maximize its weight and resistance.

A tree may be the earliest multifunctional structure, and wood is the oldest known engineering material. Yet, trees have no place in engineering education. If we view a tree from merely a mechanical or civil engineering perspective, engineering mechanics can be learned from the tree’s example. Trees have survived by adapting to the most difficult circumstances: heavy winds, rains, floods, droughts, earthquakes, mammal damage, human intervention, etc. The root system must be strong and flexible enough to support the tree’s entire structure from varying load conditions and to provide food storage and nutrient transfer. The stem system provides structural support for the tree’s above-the-ground parts and transfers water and nutrients from the roots through the network of thick-walled cells to other parts of the tree. Leaves produce food and form the surface area surrounding the tree. Leaves come in a variety of shapes and sizes. The tree’s crown, comprising branches, leaves, and reproductive elements, help the tree to catch more sunlight. It moves upward and outward to expose more of its leaves to direct sunlight for photosynthesis while maintaining physical balance on the earth. A tree’s lifecycle can span hundreds of years, despite its vulnerability to constantly changing loads throughout the day and throughout its life. In monsoon and windy seasons, trees endure extremely difficult fatigue-loading. Various parts of the tree and its stem are subjected to combined loading conditions: tension, compression, shear, bending, and torsion. Trees develop and adapt stress management strategies by adjusting their shapes to the type or level of stress they endure: they add more mass where more strength is needed, allows material to easily break off (or physiologically inactive) from locations where it is not necessary, design optimum shapes, and create variable notch radii for reducing stress concentration. But a tree is much more than a structural member. It provides food and shelter for wildlife. It absorbs atmospheric carbon dioxide and produces oxygen. It lowers air temperature and facilitates the water cycle. Structural analysis of a tree can benefit engineering students and practicing engineers alike. Furthermore, a deeper understanding of trees can help us to create multifunctional designs that are in a symbiotic relationship with other members in the system. In short, studying tree mechanics can help us to become better engineers. This paper presents our efforts to integrate trees into engineering curricula to teach mechanics ranging from equilibrium study to stress analysis. Students of statics, dynamics, the strength of materials, stress analysis, material science, design, etc., can benefit from learning about trees. This approach enables students to understand the complexities of real-world living systems, appreciate the genius of nature’s design, and develop methods for creating sustainable designs.

The failure mechanism in stretch bending over a small die radius for Advanced High Strength Steels (AHSS), commonly referred as “shear fracture”, has rendered the Forming Limit Diagrams (FLD) fail to predict it based on the initiation of a localized neck. As shown in previous studies using a Stretch-Forming Simulator (SFS) and Bending Under Tension (BUT) test, shear fracture depends not only on the radius-to-thickness (R/T) ratio but also on the tension/stretch level applied to the sheet during bending. Although the stress-base empirical fracture limit criterion was developed for various AHSS grades, the fracture limit was not well implemented in the computer simulations to predict stretch bending fracture. In this paper, the new developed experimental analysis is conducted on the modified bending under tension test to further investigate the stretch bending fracture mechanism under the production die condition. Various AHSS grades including DP590, DP780, DP980 and DP1180 are included in the study. Based on numerous experimental results, the maximum shear stress at failure, the thinning strain and strain gradient across the die radius are obtained for all test materials. Results demonstrate that the presence of the large strain gradient is the cause for fracture in stretch bending AHSS over a small die radius. The maximum shear stress at failure and the limit thinning strain on the die radius in the stretch bending condition are determined and used as the new fracture criteria, which can be easily implemented in the computer simulations.