• Thermal Induced Interface Mechanical Response Analysis of SMT Lead-Free Solder Joint and Its Adaptive Optimization

      Liu, Shaoyi; Yan, Yuefei; Zhou, Yijiang; Han, Baoqing; Wang, Benben; Zhang, Daxing; Xue, Song; Wang, Zhihai; Yu, Kunpeng; Shi, Yu; et al. (MDPI, 2022-06-08)
      Surface mount technology (SMT) plays an important role in integrated circuits, but due to thermal stress alternation caused by temperature cycling, it tends to have thermo-mechanical reliability problems. At the same time, considering the environmental and health problems of lead (Pb)-based solders, the electronics industry has turned to lead-free solders, such as ternary alloy Sn-3Ag-0.5Cu (SAC305). As lead-free solders exhibit visco-plastic mechanical properties significantly affected by temperature, their thermo-mechanical reliability has received considerable attention. In this study, the interface delamination of an SMT solder joint using a SAC305 alloy under temperature cycling has been analyzed by the nonlinear finite element method. The results indicate that the highest contact pressure at the four corners of the termination/solder horizontal interface means that delamination is most likely to occur, followed by the y-direction side region of the solder/land interface and the top arc region of the termination/solder vertical interface. It should be noted that in order to keep the shape of the solder joint in the finite element model consistent with the actual situation after the reflow process, a minimum energy-based morphology evolution method has been incorporated into the established finite element model. Eventually, an Improved Efficient Global Optimization (IEGO) method was used to optimize the geometry of the SMT solder joint in order to reduce the contact pressure at critical points and critical regions. The optimization result shows that the contact pressure at the critical points and at the critical regions decreases significantly, which also means that the probability of thermal-induced delamination decreases.
    • Numerical prediction of the chip formation and damage response in CFRP cutting with a novel strain rate based material model

      Wang, Xiaonan; Wang, Fuji; Jin, Xinghai; Fu, Rao; Shi, Yu; Dalian University of Technology; University of Chester (Elsevier, 2022-05-15)
      Carbon fibre reinforced plastics (CFRPs) are susceptible to various cutting damages. An accurate model that could efficiently predict the material removal and chip formation mechanisms will thus help to reduce the damages during cutting and further improved machining quality can be pursued. In previous studies, macro numerical models have been proposed to predict the orthogonal cutting of the CFRP laminates with subsurface damages under quasi-static loading conditions. However, the strain rate effect on the material behaviours has rarely been considered in the material modelling process, which would lead to the inaccurate prediction of the cutting process and damage extent, especially at high cutting speed. To address this issue, a novel material failure model is developed in this work by incorporating the strain rate effect across the damage initiation (combined Hashin and Puck laws) and evolution criteria. The variation in material properties with the strain rate is considered for the characterization of the stress-strain relationships under different loading speeds. With this material model, a three-dimensional macro numerical model is established to simulate the orthogonal cutting of CFRPs under four typical fibre cutting angles. The machining process and cutting force simulated by the proposed model are well agreed with the results of the CFRP orthogonal cutting experiments, and the prediction accuracy has been improved compared with the model without considering the strain rate effect. In addition, the effects of processing conditions on the subsurface damage in machining CFRPs under 135° are assessed. The subsurface damage is found to decrease with the cutting speed increases to 100 mm/s, afterwards, it tends to be stable when the cutting speed is over 100 mm/s. The increased severity of the subsurface damage is predicted with the higher cutting depths.
    • The Potential of Incremental Forming Techniques for Aerospace Applications

      de Sousa, Ricardo Alves; Afonso, Daniel; Rubino, Filice; Behera, Amar Kumar; University of Aveiro; King Juan Carlos University; University of Chester (Springer, 2022-04-26)
      Incremental sheet metal forming (ISF) processes are part of a set of non-classical techniques that allow producing low-batches, customized and/or specific geometries for advanced engineering applications, such as aerospace, automotive and biomedical parts. Combined or not with other joining processes and additive manufacturing techniques, ISF processes permit rapid prototyping frameworks, and can be included in the class of smart manufacturing processes. This chapter discusses the fundamentals of ISF technology, key attributes, future challenges and presents few examples related to the use of incremental forming for the development of complex parts as specifically found in aerospace applications such as aerofoils. The use of incremental forming to produce customized designs and to perform quick try-outs of ready-to-use parts contributes to decrease the time to market, decrease tooling cost and increase part design freedom.
    • Multifunctional cellular sandwich structures with optimised core topologies for improved mechanical properties and energy harvesting performance

      Chen, Boyue; Narita, Fumio; Wang, Congsi; Jia, Yu; Shi, Yu; Univerisity of Chester; Tohuku University; Xidian University; Aston University (Elsevier, 2022-04-13)
      This paper developed a multifunctional composite sandwich structure with optimised design on topological cores. As the main concern, full composite sandwich structures were manufactured with carbon fibre reinforced polymer (CFRP) facesheets and designed cores. Three-point bending tests have been performed to assess the mechanical performance of designed cellular sandwich structures. To evaluate the energy harvesting performance, the piezoelectric transducer was integrated at the interface between the upper facesheet and core, with both sinusoidal base excitation input and acceleration measured from real cruising aircraft and vehicle. It has been found that the sandwich with conventional honeycomb core has demonstrated the best mechanical performance, assessed under the bending tests. In terms of energy harvesting performance, sandwich with re-entrant honeycomb manifested approximately 20% higher RMS voltage output than sandwiches with conventional honeycomb and chiral structure core, evaluated both numerically and experimentally. The resistance sweep tests further suggested that the power output from sandwich with re-entrant honeycomb core was twice as large as that from sandwiches with conventional honeycomb and chiral structure cores, under optimal external resistance and sinusoidal base excitation.
    • Electromechanical characterization and kinetic energy harvesting of piezoelectric nanocomposites reinforced with glass fibers

      Maruyama, Kohei; Kawakami, Yoshihiro; Mori, Kotaro; Kurita, Hiroki; Shi, Yu; Jia, Yu; Narita, Fumio; Tohoku University; Research Institute for Electromagnetic Materials; Ibaraki University; University of Chester; Aston University (Elsevier, 2022-03-21)
      Piezoelectric composites are a significant research field because of their excellent mechanical flexibility and sufficient stress-induced voltage. Furthermore, due to the widespread use of the Internet of Things (IoT) in recent years, small-sized piezoelectric composites have attracted a lot of attention. Also, there is an urgent need to develop evaluation methods for these composites. This paper evaluates the piezoelectric and mechanical properties of potassium sodium niobate (KNN)-epoxy and KNN-glass fiber-reinforced polymer (GFRP) composites using a modified small punch (MSP) and nanoindentation tests in addition to d33 measurements. An analytical solution for the piezoelectric composite thin plate under bending was obtained for the determination of the bending properties. Due to the glass fiber inclusion, the bending strength increased by about four times, and Young's modulus in the length direction increased by approximately two times (more than that of the KNN-epoxy); however, in the thickness direction, Young's modulus decreased by less than half. An impact energy harvesting test was then performed on the KNN-epoxy and KNN-GFRP composites. As a result, the output voltage of KNN-GFRP was larger than that of KNN-epoxy. Also, the output voltage was about 2.4 V with a compressive stress of 0.2 MPa, although the presence of the glass fibers decreased the piezoelectric constants. Finally, damped flexural vibration energy harvesting test was carried out on the KNN-epoxy and KNN-GFRP composites. The KNN-epoxy was broken during the test, however KNN-GFRP composite with a load resistance of 10 generated 35 nJ of energy. Overall, through this work, we succeeded in developing piezoelectric energy harvesting composite materials that can withstand impact and bending vibration using glass fibers and also established a method for evaluating the electromechanical properties with small test specimen.
    • Multi-metric Evaluation of the Effectiveness of Remote Learning in Mechanical and Industrial Engineering During the COVID-19 Pandemic: Indicators and Guidance for Future Preparedness, 2020

      Behera, Amar Kumar; de Sousa, Ricardo Alves; Oleksik, Valentin; Dong, Jingyan; Fritzen, Daniel; University of Chester; University of Aveiro; Lucian Blaga University of Sibiu; North Carolina State University; SATC College (UK Data Service, 2021-07-27)
      This data set contains data collected from 5 universities in 5 countries about the effectiveness of e-learning during the COVID-19 pandemic, specifically tailored to mechanical and industrial engineering students. A survey was administered in May, 2020 at these universities simultaneously, using Google Forms. The survey had 41 questions, including 24 questions on a 5-point Likert scale. The survey questions gathered data on their program of study, year of study, university of enrolment and mode of accessing their online learning content. The Likert scale questions on the survey gathered data on the effectiveness of digital delivery tools, student preferences for remote learning and the success of the digital delivery tools during the pandemic. All students enrolled in modules taught by the authors of this study were encouraged to fill the survey up. Additionally, remaining students in the departments associated with the authors were also encouraged to fill up the form through emails sent on mailing lists. The survey was also advertised on external websites such as survey circle and facebook. Crucial insights have been obtained after analysing this data set that link the student demographic profile (gender, program of study, year of study, university) to their preferences for remote learning and effectiveness of digital delivery tools. This data set can be used for further comparative studies and was useful to get a snapshot of student preferences and e-learning effectiveness during the COVID-19 pandemic, which required the use of e-learning tools on a wider scale than previously and using new modes such as video conferencing that were set up within a short timeframe of a few days or weeks.
    • Non-Exhaust Vehicle Emissions of Particulate Matter and VOC from Road Traffic: A Review

      Harrison, Roy; Allan, James; Caruthers, David; Heal, Matthew; Lewis, Alastair; Marner, Ben; Murrells, Tim; Williams, Andrew; University of Birmingham; University of Manchester; Cambridge Environmental Research Consultants; University of Edinburgh; University of York; Air Quality Consultants; Ricardo Energy and Environment; University of Chester; King Abdulaziz University (Elsevier, 2021-07-01)
      As exhaust emissions of particles and volatile organic compounds (VOC) from road vehicles have progressively come under greater control, non-exhaust emissions have become an increasing proportion of the total emissions, and in many countries now exceed exhaust emissions. Non-exhaust particle emissions arise from abrasion of the brakes and tyres and wear of the road surface, as well as from resuspension of road dusts. The national emissions, particle size distributions and chemical composition of each of these sources is reviewed. Most estimates of airborne concentrations derive from the use of chemical tracers of specific emissions; the tracers and airborne concentrations estimated from their use are considered. Particle size distributions have been measured both in the laboratory and in field studies, and generally show particles to be in both the coarse (PM2.5-10) and fine (PM2.5) fractions, with a larger proportion in the former. The introduction of battery electric vehicles is concluded to have only a small effect on overall road traffic particle emissions. Approaches to numerical modelling of non-exhaust particles in the atmosphere are reviewed. Abatement measures include engineering controls, especially for brake wear, improved materials (e.g. for tyre wear) and road surface cleaning and dust suppressants for resuspension. Emissions from solvents in screen wash and de-icers now dominate VOC emissions from traffic in the UK, and exhibit a very different composition to exhaust VOC emissions. Likely future trends in non-exhaust particle emissions are described.
    • Computational simulation of the damage response for machining long fibre reinforced plastic (LFRP) composite parts: A review

      Wang, Xiaonan; Wang, Fuji; Gu, Tianyu; Jia, Zhenyuan; Shi, Yu; Dalian University of Technology; University of Chester (Elsevier, 2021-01-28)
      Long fibre reinforced plastics (LFRPs) possess excellent mechanical properties and are widely used in the aerospace, transportation and energy sectors. However, their anisotropic and inhomogeneous characteristics as well as their low thermal conductivity and specific heat capacity make them prone to subsurface damage, delamination and thermal damage during the machining process, which seriously reduces the bearing capacity and shortens the service life of the components. To improve the processing quality of composites, finite element (FE) models were developed to investigate the material removal mechanism and to analyse the influence of the processing parameters on the damage. A review of current studies on composite processing modelling could significantly help researchers to understand failure initiation and development during machining and thus inspire scholars to develop new models with high prediction accuracy and computational efficiency as well as a wide range of applications. To this aim, this review paper summarises the development of LFRP machining simulations reported in the literature and the factors that can be considered in model improvement. Specifically, the existing numerical models that simulate the mechanical and thermal behaviours of LFRPs and LFRP-metal stacks in orthogonal cutting, drilling and milling are analysed. The material models used to characterise the constituent phases of the LFRP parts are reviewed. The mechanism of material removal and the damage responses during the machining of LFRP laminates under different tool geometries and processing parameters are discussed. In addition, novel and objective evaluations that concern the current simulation studies are conducted to summarise their advantages. Aspects that could be improved are further detailed, to provide suggestions for future research relating to the simulation of LFRP machining.
    • The diagnostic analysis of the fault coupling effects in planet bearing

      Xue, Song; Wang, Congsi; Howard, Ian; Lian, Peiyuan; Chen, Gaige; Wang, yan; Yan, Yuefei; Xu, Qian; Shi, Yu; Jia, Yu; et al. (Elsevier, 2019-11-09)
      The purpose of this paper is to investigate the fault coupling effects in the planet bearing as well as the corresponding vibration signatures in the resultant vibration spectrum. In a planetary gear application, the planet bearing can not only spin around the planet gear axis, but also revolve about the sun gear axis and this rotating mechanism poses a big challenge for the diagnostic analysis of the planet bearing vibration spectrum. In addition, the frequency component interaction and overlap phenomenon in the vibration spectrum caused by the fault coupling effect can even worsen the diagnosis results. To further the understanding of the fault coupling effects in a planet bearing, a 34° of freedom planetary gear model with detailed planet bearing model was established to obtain the dynamic response in the presence of various bearing fault scenarios. The method of modelling the bearing distributed faults and localized faults has been introduced in this paper, which can be further incorporated into the planetary gear model to obtain the faulted vibration signal. The “benchmark” method has been adopted to enhance the planet bearing fault impulses in the vibration signals and in total, the amplitude demodulation results from 20 planet bearing fault scenarios have been investigated and analyzed. The coherence estimation over the vibration frequency domain has been proposed as a tool to quantify the fault impact contribution from different fault modes and the results suggested that the outer raceway fault contributes most to the resultant planet bearing vibration spectrum in all the investigated fault scenarios.
    • Integration and Characterisation of Piezoelectric Macro-Fibre Composite on Carbon Fibre Composite for Vibration Energy Harvesting

      Shi, Yu; Piao, Chenghe; Fadlaoui, Dounia; Alsaadi, Ahmed; Jia, Yu; University of Chester (IOPScience, 2019-11-01)
      Carbon fibre composite is a strong and a lightweight structural material with applications in automotive, aerospace, medical and industrial applications. The integration of piezoelectric transducer films onto the composite stack can add vibration energy harvesting capabilities to enable net-zero-power autonomous sensing for an otherwise purely mechanical structure. A PZT macro-fibre composite is co-cured with a carbon/epoxy pre-preg in order to manufacture the multi-functional composite plate. Without noticeably increasing profile, adding weight or compromising mechanical integrity, the resultant mechanical plate can recover power from vibrational excitations. With a volume of 13.5 cm3, a peak average power of 9.25 mW was recorded at 2.66 ms −2 . The normalised power density of 97 µW cm −3 m −2 s4 is comparable to some of the state-of-the-art PZT generators reported in the literature.
    • A Numerical Feasibility Study of Kinetic Energy Harvesting from Lower Limb Prosthetics

      Jia, Yu; Wei, Xueyong; Pu, Jie; Xie, Pengheng; Wen, Tao; Wang, Congsi; Lian, Peiyuan; Xue, Song; Shi, Yu; Aston University; University of Chester; Xidian University; Xi'an Jiaotong University (MDPI, 2019-10-10)
      With the advancement trend of lower limb prosthetics headed towards bionics (active ankle and knee) and smart prosthetics (gait and condition monitoring), there is an increasing integration of various sensors (micro-electromechanical system (MEMS) accelerometers, gyroscopes, magnetometers, strain gauges, pressure sensors, etc.), microcontrollers and wireless systems, and power drives including motors and actuators. All of these active elements require electrical power. However, inclusion of a heavy and bulky battery risks to undo the lightweight advancements achieved by the strong and flexible composite materials in the past decades. Kinetic energy harvesting holds the promise to recharge a small on-board battery in order to sustain the active systems without sacrificing weight and size. However, careful design is required in order not to over-burden the user from parasitic effects. This paper presents a feasibility study using measured gait data and numerical simulation in order to predict the available recoverable power. The numerical simulations suggest that, depending on the axis, up to 10s mW average electrical power is recoverable for a walking gait and up to 100s mW average electrical power is achievable during a running gait. This takes into account parasitic losses and only capturing a fraction of the gait cycle to not adversely burden the user. The predicted recoverable power levels are ample to self-sustain wireless communication and smart sensing functionalities to support smart prosthetics, as well as extend the battery life for active actuators in bionic systems. The results here serve as a theoretical foundation to design and develop towards regenerative smart bionic prosthetics.
    • Evaporation of liquid nitrogen droplets in superheated immiscible liquids

      Rebelo, Neville; Zhao, Huayong; Nadal, Francois; Garner, Colin; Williams, Andy; Loughborough University; University of Chester (Elsevier, 2019-08-22)
      Liquid nitrogen or other cryogenic liquids have the potential to replace or augment current energy sources in cooling and power applications. This can be done by the rapid evaporation and expansion processes that occur when liquid nitrogen is injected into hotter fluids in mechanical expander systems. In this study, the evaporation process of single liquid nitrogen droplets when submerged into n-propanol, methanol, n-hexane, and n-pentane maintained at 294 K has been investigated experimentally and numerically. The evaporation process is quantified by tracking the growth rate of the resulting nitrogen vapour bubble that has an interface with the bulk liquid. The experimental data suggest that the bubble volume growth is proportional to the time and the bubble growth rate is mainly determined by the initial droplet size. A comparison between the four different bulk liquids indicates that the evaporation rate in n-pentane is the highest, possibly due to its low surface tension. A scaling law based on the pure diffusion-controlled evaporation of droplet in open air environment has been successfully implemented to scale the experimental data. The deviation between the scaling law predictions and the experimental data for 2-propanol, methanol and n-hexane vary between 4% and 30% and the deviation for n-pentane was between 24% and 65%. The more detailed bubble growth rates have been modelled by a heuristic one-dimensional, spherically symmetric quasi-steady-state confined model, which can predict the growth trend well but consistently underestimate the growth rate. A fixed effective thermal conductivity is then introduced to account for the complex dynamics of the droplet inside the bubble and the subsequent convective processes in the surrounding vapour, which leads to a satisfactory quantitative prediction of the growth rate.
    • Effect of surface micro-pits on mode-II fracture toughness of Ti-6Al-4V/PEEK interface

      Pan, Lei; Pang, Xiaofei; Wang, Fei; Huang, Haiqiang; Shi, Yu; Tao, Jie; Nanjing University of Aeronautics and Astronautics; University of Chester (Elsevier, 2019-08-17)
      Herein, the delamination issue of TiGr(TC4/PEEK/Cf) laminate is addressed by investigating the influence of TC4(Ti-6Al-4V) surface micro-pits on mode-II interfacial fracture toughness of TC4/PEEK interface through experimental and finite element modeling. The micro-pits unit cell, unit strip and the end notched flexure (ENF) models are established based on the finite element simulations and the effect of micro-pit size parameters is studied in detail. The results of micro-pits unit cell model reveal that the presence of micro-pits can effectively buffer the interfacial stress concentration under mode-II loading conditions. Furthermore, the micro-pits unit strip model, with different micro-pit sizes, is analyzed to obtain the interface parameters, which are converted and used in the ENF model. Both the unit strip and ENF models conclude that the presence of interfacial micro-pits effectively improves the mode-II fracture toughness. It is worth mentioning that the utilization of converted interface parameters in ENF model avoided the limitation of micro-pit size and reduced the workload. Finally, the experimental and computational ENF results exhibited excellent consistency and confirmed the reliability of the proposed finite element models. The current study provides useful guidelines for the design and manufacturing of high-performance TC4/PEEK interfaces for a wide range of applications.
    • Surface adjustment strategy for a large radio telescope with adjustable dual reflectors

      Lian, Peiyuan; Wang, Congsi; Xue, Song; Xu, Qian; Shi, Yu; Jia, Yu; Xiang, Binbin; Wang, Yan; Yan, Yuefei; Xidian University; University of Chester; Chinese Academy of Sciences (IET, 2019-08-15)
      With the development of large-aperture and high-frequency radio telescopes, a surface adjustment procedure for the compensation of surface deformations has become of great importance. In this study, an innovative surface adjustment strategy is proposed to achieve an automated adjustment for the large radio telescope with adjustable dual reflectors. In the proposed strategy, a high-precision and long-distance measurement instrument is adopted and installed on the back of the sub-reflector to measure the distances and elevation angles of the target points on the main reflector. Here, two surface adjustment purposes are discussed. The first purpose is to ensure that the main reflector and sub-reflector are always positioned at their ideal locations during operation. The second purpose is to adjust the main reflector to the location of the best fitting reflector, and the sub-reflector to the focus of the best fitting reflector. Next, the calculation procedures for the adjustments of the main reflector and the sub-reflector are discussed in detail, and corresponding simulations are carried out to verify the proposed method. The results show that the proposed strategy is effective. This study can provide helpful guidance for the design of automated surface adjustments for large telescopes.
    • Delamination Detection via Reconstructed Frequency Response Function of Composite Structures

      Shi, Yu; Alsaadi, Ahmed; Jia, Yu; University of Chester (Springer, 2019-07-05)
      Online damage detection technologies could reduce the weight of structures by allowing the use of less conservative margins of safety. They are also associated with high economical benefits by implementing a condition-based maintenance system. This paper presented a damage detection and location technique based on the dynamic response of glass fibre composite laminate structures (frequency response function). Glass fibre composite laminate plates of 200×200×2.64 mm, which had a predefined delamination, were excited using stationary random vibration waves of 500 Hz band-limited noise input at ≈1.5 g. The response of the structure was captured via Micro-ElectroMechanical System (MEMS) accelerometer to detect damage. The frequency response function requires data from damaged structures only, assuming that healthy structures are homogeneous and smooth. The frequency response of the composite structure was then reconstructed and fitted using the least-squares rational function method. Delamination as small as 20 mm was detected using global changes in the natural frequencies of the structure, the delamination was also located with greater degree of accuracy due to local changes of frequency response of the structure. It was concluded that environmental vibration waves (stationary random vibration waves) can be utilised to monitor damage and health of composite structures effectively.
    • Enhancement in Interfacial Adhesion of Ti/Polyetheretherketone by Electrophoretic Deposition of Graphene Oxide

      Pan, Lei; Lv, Yunfei; Nipon, Roy; Wang, Yifan; Duan, Lixiang; Hu, Jingling; Ding, Wenye; Ma, Wenliang; Tao, Jie; Shi, Yu; et al. (Wiley, 2019-03-24)
      This article discusses about the significance of graphene oxide (GO) deposition on the surface of a titanium plate by electrophoretic deposition (EPD) method to improve the adhesive strength of Ti/polyetheretherketone (PEEK) interfacial adhesive. Firstly, the anodic EPD method was applied to a water dispersion solution of GO, and then the morphology and the properties of titanium plate surface were characterized by scanning electron microscopy and contact angle measurements before and after GO deposition. Furthermore, the changes in the properties of GO after heating at 390°C were characterized by Raman and Fourier transform infrared spectroscopies. According to the results of single lap tensile shear test, the adhesion strength of Ti/PEEK interface after the anodization and deposition of GO was 34.94 MPa, an increase of 29.2% compared with 27.04 MPa of sample with only anodization. Also, the adhesion strengths were 58.1 and 76.5% higher compared with the samples of only GO deposited (22.1 MPa) and pure titanium (19.8 MPa), respectively.
    • Gradient-based optimization method for producing a contoured beam with single-fed reflector antenna

      Lian, Peiyuan; Wang, Congsi; Xiang, Binbin; Shi, Yu; Xue, Song; Xidian University; University of Chester; Chinese Academy of Sciences (IEEE, 2019-03-07)
      A gradient-based optimization method for producing a contoured beam by using a single-fed reflector antenna is presented. First, a quick and accurate pattern approximation formula based on physical optics (PO) is adopted to calculate the gradients of the directivity with respect to reflector's nodal displacements. Because the approximation formula is a linear function of nodal displacements, the gradient can be easily derived. Then, the method of the steepest descent is adopted, and an optimization iteration procedure is proposed. The iteration procedure includes two loops: an inner loop and an outer loop. In the inner loop, the gradient and pattern are calculated by matrix operation, which is very fast by using the pre-calculated data in the outer loop. In the outer loop, the ideal terms used in the inner loop to calculate the gradient and pattern are updated, and the real pattern is calculated by the PO method. Due to the high approximation accuracy, when the outer loop is performed once, the inner loop can be performed many times, which will save much time because the integration is replaced by matrix operation. In the end, a contoured beam covering the continental United States (CONUS) is designed, and simulation results show the effectiveness of the proposed algorithm.
    • Multiphysics vibration FE model of piezoelectric macro fibre composite on carbon fibre composite structures

      Jia, Yu; Wei, Xueyong; Xu, Liu; Wang, Congsi; Lian, Peiyuan; Xue, Song; Alsaadi, Ahmed; Shi, Yu; University of Chester; Xi'an Jiaotong University; Xidian University (Elsevier, 2018-12-21)
      This paper presents a finite element (FE) model developed using commercial FE software COMSOL to simulate the multiphysical process of pieozoelectric vibration energy harvesting (PVEH), involving the dynamic mechanical and electrical behaviours of piezoelectric macro fibre composite (MFC) on carbon fibre composite structures. The integration of MFC enables energy harvesting, sensing and actuation capabilities, with applications found in aerospace, automotive and renewable energy. There is an existing gap in the literature on modelling the dynamic response of PVEH in relation to real-world vibration data. Most simulations were either semi-analytical MATLAB models that are geometry unspecific, or basic FE simulations limited to sinusoidal analysis. However, the use of representative environment vibration data is crucial to predict practical behaviour for industrial development. Piezoelectric device physics involving solid mechanics and electrostatics were combined with electrical circuit defined in this FE model. The structure was dynamically excited by interpolated vibration data files, while orthotropic material properties for MFC and carbon fibre composite were individually defined for accuracy. The simulation results were validated by experiments with <10﹪ deviation, providing confidence for the proposed multiphysical FE model to design and optimise PVEH smart composite structures.
    • Rapid, Chemical-Free Generation of Optically Scattering Structures in Poly(ethylene terephthalate) Using a CO2 Laser for Lightweight and Flexible Photovoltaic Applications

      Academic Editor: Yan, Yanfa; Hodgson, Simon D.; Gillett, Alice R. (Hindawi, 2018-12-16)
      Highly light scattering structures have been generated in a poly(ethylene terephthalate) (PET) film using a CO2 laser. The haze, and in some cases the transparency, of the PET films have been improved by varying the processing parameters of the laser (namely, scanning velocity, laser output power, and spacing between processed tracks). When compared with the unprocessed PET, the haze has improved from an average value of 3.26% to a peak of 55.42%, which equates to an absolute improvement of 52.16% or a 17-fold increase. In addition to the optical properties, the surfaces have been characterised using optical microscopy and mapped with an optical profilometer. Key surface parameters that equate to the amount and structure of surface roughness and features have been analysed. The CO2 laser generates microstructures at high speed, without affecting the bulk properties of the material, and is inherently a chemical-free process making it particularly applicable for use in industry, fitting well with the high-throughput, roll to roll processes associated with the production of flexible organic photovoltaic devices.
    • An Analytical and Numerical Study of Magnetic Spring Suspension with Energy Recovery Capabilities

      Jia, Yu; Li, Shasha; Shi, Yu; University of Chester; China National Intellectual Property Administration (MDPI, 2018-11-12)
      As the automotive paradigm shifts towards electric, limited range remains a key challenge. Increasing the battery size adds weight, which yields diminishing returns in range per kilowatt-hour. Therefore, energy recovery systems, such as regenerative braking and photovoltaic cells, are desirable to recharge the onboard batteries in between hub charge cycles. While some reports of regenerative suspension do exist, they all harvest energy in a parasitic manner, and the predicted power output is extremely low, since the majority of the energy is still dissipated to the environment by the suspension. This paper proposes a fundamental suspension redesign using a magnetically-levitated spring mechanism and aims to increase the recoverable energy significantly by directly coupling an electromagnetic transducer as the main damper. Furthermore, the highly nonlinear magnetic restoring force can also potentially enhance rider comfort. Analytical and numerical models have been constructed. Road roughness data from an Australian road were used to numerically simulate a representative environment response. Simulation suggests that 10’s of kW to >100 kW can theoretically be generated by a medium-sized car travelling on a typical paved road (about 2–3 orders of magnitude higher than literature reports on parasitic regenerative suspension schemes), while still maintaining well below the discomfort threshold for passengers (<0.315 m/s2 on average).