Package Design Thermal Optimization for Metal-Oxide Gas Sensors by Finite Element Modeling and Infra-Red Imaging Characterization

We designed a 3D geometrical model of a metal-oxide gas sensor and its custom packaging and used it in finite element modeling (FEM) analysis for obtaining temperature and heat flux distribution. The 3D computer simulation, performed with GetDP software (version 3.5.0, 13 May 2022), accurately predicted the temperature distribution variation across the entire assembly. Knowing the temperature variation and the location of the hot spots allowed us to select the best electrical interconnect method and to choose the optimal materials combination and optimal geometry. The thermal modeling also confirmed the need to use a low thermal conductivity material to insulate the MOX sensor since the latter is heated to its operational temperature of 250 °C. For that purpose, we used the in-house formulated xerogel-epoxy composite of thermal conductivity of 0.108 W m-1 K-1, which is at least 30% less compared to the best-in-class among commercially available materials. Based on the 3D FEM outputs, we designed, assembled, and characterized a fully functional packaged MOX gas sensor in several configurations. We measured the temperature distribution on all parts of the MOX gas sensor assembly using a thermal imaging infrared (IR) microscope. The results of 3D FEM are in good agreement with the temperature distribution obtained by the non-contact IR thermal characterization.

On the Role of Damage Evolution in Finite Element Modeling of the Cutting Process and Sensing Residual Stresses

This study focuses on the role of the damage evolution when estimating the failure behavior of AISI 1045 steel for sensing and measuring metal cutting parameters. A total of five Lagrangian explicit models are established to investigate the effect of applying damage evolution techniques. The Johnson-Cook failure model is introduced once to fully represent damage behavior, i.e., no damage evolution is considered, and as a damage initiation criterion in the remaining approaches. A fracture energy-based model is included to model damage propagation with different evolution rates. Temperature-dependent and temperature-independent fracture energy models are also investigated. Dry orthogonal cutting and residual stresses measurements of AISI 1045 are conducted for validation. The significance of the damage evolution is investigated using honed-tool and sharp-tool models. Including the damage evolution led to a prediction of higher workpiece temperatures, plastic strains, cutting forces, and residual stresses, with no clear differences between linear and exponential evolution rates. The role of damage evolution is more evident when temperature-dependent evolution models are used.

Deformation Behavior of Elastomer-Glass Fiber-Reinforced Plastics in Dependence of Pneumatic Actuation

This paper aims to define the influencing design criteria for compliant folding mechanisms with pneumatically actuated hinges consisting of fiber-reinforced plastic (FRP). Through simulation and physical testing, the influence of stiffness, hinge width as well as variation of the stiffness, in the flaps without changing the stiffness in the hinge zone, was evaluated. Within a finite element model software, a workflow was developed for simulations, in order to infer mathematical models for the prediction of mechanical properties and the deformation behavior as a function of the aforementioned parameters. In conclusion, the bending angle increases with decreasing material stiffness and with increasing hinge width, while it is not affected by the flap stiffness itself. The defined workflow builds a basis for the development of a predictive model for the deformation behavior of FRPs.

Increasing Necking Strain through Corrugation: Identifying Composite Systems That Can Benefit from Corrugated Geometry

Under some circumstances, composites with a corrugated reinforcement geometry show larger necking strains compared to traditional straight reinforced composites. In this work, finite element modeling studies were performed for linearly hardening materials, examining the effect of material parameters on the stress–strain response of both corrugation and straight-reinforced composites. These studies showed that improvements in necking strain depend on the ability of the corrugation to unbend and to provide a boost in work hardening at the right time. It was found that there is a range of matrix yield strengths and hardening rates for which a corrugated geometry will improve the necking strain and also a lower threshold of reinforcement yield strength below which no improvement in necking strain is possible. In addition, benefit maps and surfaces were generated that show which regions of property space benefit through corrugation and the corresponding improvement in necking strain that can be achieved.

Numerical Simulations of Laser and Hybrid S700MC T-Joint Welding

This article presents examples of numerical simulations done based on the real experiments of S700MC steel T-joint laser and hybrid welding. Presented results of numerical analyses carried out using SYSWELD show the possibilities offered to contemporary engineers by modern software used to make numerical analyses of production processes. After calibration of a heat source models on the chosen examples of S700MC steel 10-mm-thick T-joint laser and hybrid welding, distributions of temperature fields, thermal cycles, distributions of individual metallurgical phases and hardness, and strains and plastic deformations in simulated processes were calculated for one selected joint from both mentioned methods. The results of the analysis allow determining both the differences in the stress distributions and their minimal and maximal values. This article also presents the benefits resulting from the use of such analyses, due to the significant savings in time and resources to be spent on the development of correct technologies for joining modern construction materials such as thermomechanically treated steels, especially given that some of the results are unavailable or very difficult to collect using conventional measurement methods.

Automatic multi-parametric quantification of the proximal femur with quantitative computed tomography

BACKGROUND

Quantitative computed tomography (QCT) imaging is the basis for multiple assessments of bone quality in the proximal femur, including volumetric bone mineral density (vBMD), tissue volume, estimation of bone strength using finite element modeling (FEM), cortical bone thickness, and computational-anatomy-based morphometry assessments.

METHODS

Here, we present an automatic framework to perform a multi-parametric QCT quantification of the proximal femur. In this framework, the proximal femur is cropped from the bilateral hip scans, segmented using a multi-atlas based segmentation approach, and then assigned volumes of interest through the registration of a proximal femoral template. The proximal femur is then subjected to compartmental vBMD, compartmental tissue volume, FEM bone strength, compartmental surface-based cortical bone thickness, compartmental surface-based vBMD, local surface-based cortical bone thickness, and local surface-based cortical vBMD computations. Consequently, the template registrations together with vBMD and surface-based cortical bone parametric maps enable computational anatomy studies. The accuracy of the segmentation was validated against manual segmentations of 80 scans from two clinical facilities, while the multi-parametric reproducibility was evaluated using repeat scans with repositioning from 22 subjects obtained on CT imaging systems from two manufacturers.

RESULTS

Accuracy results yielded a mean dice similarity coefficient of 0.976±0.006, and a modified Haussdorf distance of 0.219±0.071 mm. Reproducibility of QCT-derived parameters yielded root mean square coefficients of variation (CVRMS) between 0.89-1.66% for compartmental vBMD; 0.20-1.82% for compartmental tissue volume; 3.51-3.59% for FEM bone strength; 1.89-2.69% for compartmental surface-based cortical bone thickness; and 1.08-2.19% for compartmental surface-based cortical vBMD. For local surface-based assessments, mean CVRMS were between 3.45-3.91% and 2.74-3.15% for cortical bone thickness and vBMD, respectively.

CONCLUSIONS

The automatic framework presented here enables accurate and reproducible QCT multi-parametric analyses of the proximal femur. Our subjects were elderly, with scans obtained across multiple clinical sites and manufacturers, thus documenting its value for clinical trials and other multi-site studies.