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- All Subjects: Mechanical Engineering
- Genre: Academic theses
- Genre: Masters Thesis
- Creators: Liu, Yongming
Description
This research examines the current challenges of using Lamb wave interrogation methods to localize fatigue crack damage in a complex metallic structural component subjected to unknown temperatures. The goal of this work is to improve damage localization results for a structural component interrogated at an unknown temperature, by developing a probabilistic and reference-free framework for estimating Lamb wave velocities and the damage location. The methodology for damage localization at unknown temperatures includes the following key elements: i) a model that can describe the change in Lamb wave velocities with temperature; ii) the extension of an advanced time-frequency based signal processing technique for enhanced time-of-flight feature extraction from a dispersive signal; iii) the development of a Bayesian damage localization framework incorporating data association and sensor fusion. The technique requires no additional transducers to be installed on a structure, and allows for the estimation of both the temperature and the wave velocity in the component. Additionally, the framework of the algorithm allows it to function completely in an unsupervised manner by probabilistically accounting for all measurement origin uncertainty. The novel algorithm was experimentally validated using an aluminum lug joint with a growing fatigue crack. The lug joint was interrogated using piezoelectric transducers at multiple fatigue crack lengths, and at temperatures between 20°C and 80°C. The results showed that the algorithm could accurately predict the temperature and wave speed of the lug joint. The localization results for the fatigue damage were found to correlate well with the true locations at long crack lengths, but loss of accuracy was observed in localizing small cracks due to time-of-flight measurement errors. To validate the algorithm across a wider range of temperatures the electromechanically coupled LISA/SIM model was used to simulate the effects of temperatures. The numerical results showed that this approach would be capable of experimentally estimating the temperature and velocity in the lug joint for temperatures from -60°C to 150°C. The velocity estimation algorithm was found to significantly increase the accuracy of localization at temperatures above 120°C when error due to incorrect velocity selection begins to outweigh the error due to time-of-flight measurements.
ContributorsHensberry, Kevin (Author) / Chattopadhyay, Aditi (Thesis advisor) / Liu, Yongming (Committee member) / Papandreou-Suppappola, Antonia (Committee member) / Arizona State University (Publisher)
Created2013
Description
This thesis concerns the role of geometric imperfections on assemblies in which the location of a target part is dependent on supports at two features. In some applications, such as a turbo-machine rotor that is supported by a series of parts at each bearing, it is the interference or clearance at a functional target feature, such as at the blades that must be controlled. The first part of this thesis relates the limits of location for the target part to geometric imperfections of other parts when stacked-up in parallel paths. In this section parts are considered to be rigid (non-deformable). By understanding how much of variation from the supporting parts contribute to variations of the target feature, a designer can better utilize the tolerance budget when assigning values to individual tolerances. In this work, the T-Map®, a spatial math model is used to model the tolerance accumulation in parallel assemblies. In other applications where parts are flexible, deformations are induced when parts in parallel are clamped together during assembly. Presuming that perfectly manufactured parts have been designed to fit perfectly together and produce zero deformations, the clamping-induced deformations result entirely from the imperfect geometry that is produced during manufacture. The magnitudes and types of these deformations are a function of part dimensions and material stiffnesses, and they are limited by design tolerances that control manufacturing variations. These manufacturing variations, if uncontrolled, may produce high enough stresses when the parts are assembled that premature failure can occur before the design life. The last part of the thesis relates the limits on the largest von Mises stress in one part to functional tolerance limits that must be set at the beginning of a tolerance analysis of parts in such an assembly.
ContributorsJaishankar, Lupin Niranjan (Author) / Davidson, Joseph K. (Thesis advisor) / Shah, Jami J. (Committee member) / Mignolet, Marc P (Committee member) / Arizona State University (Publisher)
Created2012
Description
Tolerances on line profiles are used to control cross-sectional shapes of parts, such as turbine blades. A full life cycle for many mechanical devices depends (i) on a wise assignment of tolerances during design and (ii) on careful quality control of the manufacturing process to ensure adherence to the specified tolerances. This thesis describes a new method for quality control of a manufacturing process by improving the method used to convert measured points on a part to a geometric entity that can be compared directly with tolerance specifications. The focus of this paper is the development of a new computational method for obtaining the least-squares fit of a set of points that have been measured with a coordinate measurement machine along a line-profile. The pseudo-inverse of a rectangular matrix is used to convert the measured points to the least-squares fit of the profile. Numerical examples are included for convex and concave line-profiles, that are formed from line- and circular arc-segments.
ContributorsSavaliya, Samir (Author) / Davidson, Joseph K. (Thesis advisor) / Shah, Jami J. (Committee member) / Santos, Veronica J (Committee member) / Arizona State University (Publisher)
Created2013
Description
Creative design lies at the intersection of novelty and technical feasibility. These objectives can be achieved through cycles of divergence (idea generation) and convergence (idea evaluation) in conceptual design. The focus of this thesis is on the latter aspect. The evaluation may involve any aspect of technical feasibility and may be desired at component, sub-system or full system level. Two issues that are considered in this work are: 1. Information about design ideas is incomplete, informal and sketchy 2. Designers often work at multiple levels; different aspects or subsystems may be at different levels of abstraction Thus, high fidelity analysis and simulation tools are not appropriate for this purpose. This thesis looks at the requirements for a simulation tool and how it could facilitate concept evaluation. The specific tasks reported in this thesis are: 1. The typical types of information available after an ideation session 2. The typical types of technical evaluations done in early stages 3. How to conduct low fidelity design evaluation given a well-defined feasibility question A computational tool for supporting idea evaluation was designed and implemented. It was assumed that the results of the ideation session are represented as a morphological chart and each entry is expressed as some combination of a sketch, text and references to physical effects and machine components. Approximately 110 physical effects were identified and represented in terms of algebraic equations, physical variables and a textual description. A common ontology of physical variables was created so that physical effects could be networked together when variables are shared. This allows users to synthesize complex behaviors from simple ones, without assuming any solution sequence. A library of 16 machine elements was also created and users were given instructions about incorporating them. To support quick analysis, differential equations are transformed to algebraic equations by replacing differential terms with steady state differences), only steady state behavior is considered and interval arithmetic was used for modeling. The tool implementation is done by MATLAB; and a number of case studies are also done to show how the tool works. textual description. A common ontology of physical variables was created so that physical effects could be networked together when variables are shared. This allows users to synthesize complex behaviors from simple ones, without assuming any solution sequence. A library of 15 machine elements was also created and users were given instructions about incorporating them. To support quick analysis, differential equations are transformed to algebraic equations by replacing differential terms with steady state differences), only steady state behavior is considered and interval arithmetic was used for modeling. The tool implementation is done by MATLAB; and a number of case studies are also done to show how the tool works.
ContributorsKhorshidi, Maryam (Author) / Shah, Jami J. (Thesis advisor) / Wu, Teresa (Committee member) / Gel, Esma (Committee member) / Arizona State University (Publisher)
Created2014
Description
Aluminum alloys and their composites are attractive materials for applications requiring high strength-to-weight ratios and reasonable cost. Many of these applications, such as those in the aerospace industry, undergo fatigue loading. An understanding of the microstructural damage that occurs in these materials is critical in assessing their fatigue resistance. Two distinct experimental studies were performed to further the understanding of fatigue damage mechanisms in aluminum alloys and their composites, specifically fracture and plasticity. Fatigue resistance of metal matrix composites (MMCs) depends on many aspects of composite microstructure. Fatigue crack growth behavior is particularly dependent on the reinforcement characteristics and matrix microstructure. The goal of this work was to obtain a fundamental understanding of fatigue crack growth behavior in SiC particle-reinforced 2080 Al alloy composites. In situ X-ray synchrotron tomography was performed on two samples at low (R=0.1) and at high (R=0.6) R-ratios. The resulting reconstructed images were used to obtain three-dimensional (3D) rendering of the particles and fatigue crack. Behaviors of the particles and crack, as well as their interaction, were analyzed and quantified. Four-dimensional (4D) visual representations were constructed to aid in the overall understanding of damage evolution. During fatigue crack growth in ductile materials, a plastic zone is created in the region surrounding the crack tip. Knowledge of the plastic zone is important for the understanding of fatigue crack formation as well as subsequent growth behavior. The goal of this work was to quantify the 3D size and shape of the plastic zone in 7075 Al alloys. X-ray synchrotron tomography and Laue microdiffraction were used to non-destructively characterize the volume surrounding a fatigue crack tip. The precise 3D crack profile was segmented from the reconstructed tomography data. Depth-resolved Laue patterns were obtained using differential-aperture X-ray structural microscopy (DAXM), from which peak-broadening characteristics were quantified. Plasticity, as determined by the broadening of diffracted peaks, was mapped in 3D. Two-dimensional (2D) maps of plasticity were directly compared to the corresponding tomography slices. A 3D representation of the plastic zone surrounding the fatigue crack was generated by superimposing the mapped plasticity on the 3D crack profile.
ContributorsHruby, Peter (Author) / Chawla, Nikhilesh (Thesis advisor) / Solanki, Kiran (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2014
Description
Dimensional Metrology is the branch of science that determines length, angular, and geometric relationships within manufactured parts and compares them with required tolerances. The measurements can be made using either manual methods or sampled coordinate metrology (Coordinate measuring machines). Manual measurement methods have been in practice for a long time and are well accepted in the industry, but are slow for the present day manufacturing. On the other hand CMMs are relatively fast, but these methods are not well established yet. The major problem that needs to be addressed is the type of feature fitting algorithm used for evaluating tolerances. In a CMM the use of different feature fitting algorithms on a feature gives different values, and there is no standard that describes the type of feature fitting algorithm to be used for a specific tolerance. Our research is focused on identifying the feature fitting algorithm that is best used for each type of tolerance. Each algorithm is identified as the one to best represent the interpretation of geometric control as defined by the ASME Y14.5 standard and on the manual methods used for the measurement of a specific tolerance type. Using these algorithms normative procedures for CMMs are proposed for verifying tolerances. The proposed normative procedures are implemented as software. Then the procedures are verified by comparing the results from software with that of manual measurements.
To aid this research a library of feature fitting algorithms is developed in parallel. The library consists of least squares, Chebyshev and one sided fits applied on the features of line, plane, circle and cylinder. The proposed normative procedures are useful for evaluating tolerances in CMMs. The results evaluated will be in accordance to the standard. The ambiguity in choosing the algorithms is prevented. The software developed can be used in quality control for inspection purposes.
To aid this research a library of feature fitting algorithms is developed in parallel. The library consists of least squares, Chebyshev and one sided fits applied on the features of line, plane, circle and cylinder. The proposed normative procedures are useful for evaluating tolerances in CMMs. The results evaluated will be in accordance to the standard. The ambiguity in choosing the algorithms is prevented. The software developed can be used in quality control for inspection purposes.
ContributorsVemulapalli, Prabath (Author) / Shah, Jami J. (Thesis advisor) / Davidson, Joseph K. (Committee member) / Takahashi, Timothy (Committee member) / Arizona State University (Publisher)
Created2014
Description
The focus of this investigation is on the formulation and a validation of reduced order models (ROMs) for the prediction of the response of structures with embedded piezoelectric actuators. The ROMs considered here are those constructed in a nonintrusive manner from a commercial finite element software, NASTRAN is adopted here. Notwithstanding the popularity of piezoelectric materials in structural dynamics related applications such as structural health monitoring and energy harvesting, not all commercial finite element software allow directly their modeling. In such cases, e.g., with NASTRAN, one can proceed with an analogy and replace the electric actuation in the piezoelectric material by a fictitious thermal effect producing the same strain. This process recasts the determination of a ROM for a structure with embedded piezoelectric actuator into a similar ROM but for a heated structure, the framework of which has recently been developed. Yet, the temperature field resulting from the analogy would be quite different from the one considered in past effort and would excite a broad array of structural modes. Accordingly, as a preamble to considering a beam with a piezoelectric layer, a simpler plate model is considered that is subjected to a uniform temperature but a complex pressure loading that excites the entire set of modes of the plate in the broad frequency band considered. The very good match of the predictions obtained by this ROM in comparison to their full finite element counterparts provides the necessary confidence to next address a beam with embedded piezoelectic actuator. The test model considered for this validation is a built-up nano beam analyzed recently in nonlinear geometric conditions by full finite elements and by a non-intrusive ROM procedure under harmonic variations of the piezoelectic voltage. This structural model and its loading conditions are very different from those considered in past applications of nonintrusive ROMs, thus the excellent results obtained here provide further support of the broad generality of the nonintrusive ROM methodology, including of the appropriateness of the "dual modes" basis functions.
ContributorsVyas, Varun (Author) / Mignolet, Marc (Thesis advisor) / Hollkamp, Joseph (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2014
Description
Conceptual design stage plays a critical role in product development. However, few systematic methods and tools exist to support conceptual design. The long term aim of this project is to develop a tool for facilitating holistic ideation for conceptual design. This research is a continuation of past efforts in ASU Design Automation Lab. In past research, an interactive software test bed (Holistic Ideation Tool - version 1) was developed to explore logical ideation methods. Ideation states were identified and ideation strategies were developed to overcome common ideation blocks. The next version (version 2) of the holistic ideation tool added Cascading Evolutionary Morphological Charts (CEMC) framework and intuitive ideation strategies (reframing, restructuring, random connection, and forced connection).
Despite these remarkable contributions, there exist shortcomings in the previous versions (version 1 and version 2) of the holistic ideation tool. First, there is a need to add new ideation methods to the holistic ideation tool. Second, the organizational framework provided by previous versions needs to be improved, and a holistic approach needs to be devised, instead of separate logical or intuitive approaches. Therefore, the main objective of this thesis is to make the improvements and to resolve technical issues that are involved in their implementation.
Towards this objective, a new web based holistic ideation tool (version 3) has been created. The new tool adds and integrates Knowledge Bases of Mechanisms and Components Off-The-Shelf (COTS) into logical ideation methods. Additionally, an improved CEMC framework has been devised for organizing ideas efficiently. Furthermore, the usability of the tool has been improved by designing and implementing a new graphical user interface (GUI) which is more user friendly. It is hoped that these new features will lead to a platform for the designers to not only generate creative ideas but also effectively organize and store them in the conceptual design stage. By placing it on the web for public use, the Testbed has the potential to be used for research on the ideation process by effectively collecting large amounts of data from designers.
Despite these remarkable contributions, there exist shortcomings in the previous versions (version 1 and version 2) of the holistic ideation tool. First, there is a need to add new ideation methods to the holistic ideation tool. Second, the organizational framework provided by previous versions needs to be improved, and a holistic approach needs to be devised, instead of separate logical or intuitive approaches. Therefore, the main objective of this thesis is to make the improvements and to resolve technical issues that are involved in their implementation.
Towards this objective, a new web based holistic ideation tool (version 3) has been created. The new tool adds and integrates Knowledge Bases of Mechanisms and Components Off-The-Shelf (COTS) into logical ideation methods. Additionally, an improved CEMC framework has been devised for organizing ideas efficiently. Furthermore, the usability of the tool has been improved by designing and implementing a new graphical user interface (GUI) which is more user friendly. It is hoped that these new features will lead to a platform for the designers to not only generate creative ideas but also effectively organize and store them in the conceptual design stage. By placing it on the web for public use, the Testbed has the potential to be used for research on the ideation process by effectively collecting large amounts of data from designers.
ContributorsNarsale, Sumit Sunil (Author) / Shah, Jami J. (Thesis advisor) / Davidson, Joseph K. (Committee member) / Wu, Teresa (Committee member) / Arizona State University (Publisher)
Created2014
Description
The main objective of this project was to create a framework for holistic ideation and research about the technical issues involved in creating a holistic approach. Towards that goal, we explored different components of ideation (both logical and intuitive), characterized ideation states, and found new ideation blocks with strategies used to overcome them. One of the major contributions of this research is the method by which easy traversal between different ideation methods with different components were facilitated, to support both creativity and functional quality. Another important part of the framework is the sensing of ideation states (blocks/ unfettered ideation) and investigation of matching ideation strategies most likely to facilitate progress. Some of the ideation methods embedded in the initial holistic test bed are Physical effects catalog, working principles catalog, TRIZ, Bio-TRIZ and Artifacts catalog. Repositories were created for each of those. This framework will also be used as a research tool to collect large amount of data from designers about their choice of ideation strategies used, and their effectiveness. Effective documentation of design ideation paths is also facilitated using this holistic approach. A computer tool facilitating holistic ideation was developed. Case studies were run on different designers to document their ideation states and their choice of ideation strategies to come up with a good solution to solve the same design problem.
ContributorsMohan, Manikandan (Author) / Shah, Jami J. (Thesis advisor) / Huebner, Kenneth (Committee member) / Burleson, Winslow (Committee member) / Arizona State University (Publisher)
Created2011
Description
The objective of this research is to develop robust, accurate, and adaptive algorithms in the framework of the extended finite element method (XFEM) for fracture analysis of highly heterogeneous materials with complex internal geometries. A key contribution of this work is the creation of novel methods designed to automate the incorporation of high-resolution data, e.g. from X-ray tomography, that can be used to better interpret the enormous volume of data generated in modern in-situ experimental testing. Thus new algorithms were developed for automating analysis of complex microstructures characterized by segmented tomographic images.
A centrality-based geometry segmentation algorithm was developed to accurately identify discrete inclusions and particles in composite materials where limitations in imaging resolution leads to spurious connections between particles in close contact.To allow for this algorithm to successfully segment geometry independently of particle size and shape, a relative centrality metric was defined to allow for a threshold centrality criterion for removal of voxels that spuriously connect distinct geometries.
To automate incorporation of microstructural information from high-resolution images, two methods were developed that initialize signed distance fields on adaptively-refined finite element meshes. The first method utilizes a level set evolution equation that is directly solved on the finite element mesh through Galerkins method. The evolution equation is formulated to produce a signed distance field that matches geometry defined by a set of voxels segmented from tomographic images. The method achieves optimal convergence for the order of elements used. In a second approach, the fast marching method is employed to initialize a distance field on a uniform grid which is then projected by least squares onto a finite element mesh. This latter approach is shown to be superior in speed and accuracy.
Lastly, extended finite element method simulations are performed for the analysis of particle fracture in metal matrix composites with realistic particle geometries initialized from X-ray tomographic data. In the simulations, particles fracture probabilistically through a Weibull strength distribution. The model is verified through comparisons with the experimentally-measured stress-strain response of the material as well as analysis of the fracture. Further, simulations are then performed to analyze the effect of mesh sensitivity, the effect of fracture of particles on their neighbors, and the role of a particles shape on its fracture probability.
A centrality-based geometry segmentation algorithm was developed to accurately identify discrete inclusions and particles in composite materials where limitations in imaging resolution leads to spurious connections between particles in close contact.To allow for this algorithm to successfully segment geometry independently of particle size and shape, a relative centrality metric was defined to allow for a threshold centrality criterion for removal of voxels that spuriously connect distinct geometries.
To automate incorporation of microstructural information from high-resolution images, two methods were developed that initialize signed distance fields on adaptively-refined finite element meshes. The first method utilizes a level set evolution equation that is directly solved on the finite element mesh through Galerkins method. The evolution equation is formulated to produce a signed distance field that matches geometry defined by a set of voxels segmented from tomographic images. The method achieves optimal convergence for the order of elements used. In a second approach, the fast marching method is employed to initialize a distance field on a uniform grid which is then projected by least squares onto a finite element mesh. This latter approach is shown to be superior in speed and accuracy.
Lastly, extended finite element method simulations are performed for the analysis of particle fracture in metal matrix composites with realistic particle geometries initialized from X-ray tomographic data. In the simulations, particles fracture probabilistically through a Weibull strength distribution. The model is verified through comparisons with the experimentally-measured stress-strain response of the material as well as analysis of the fracture. Further, simulations are then performed to analyze the effect of mesh sensitivity, the effect of fracture of particles on their neighbors, and the role of a particles shape on its fracture probability.
ContributorsYuan, Rui (Author) / Oswald, Jay (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Liu, Yongming (Committee member) / Solanki, Kiran (Committee member) / Chen, Kangping (Committee member) / Arizona State University (Publisher)
Created2015