Virtual product development and testing for aerospace tube hydroforming industry : improved non-linear solid-shell element

Authors: Elie-dit-Cosaque, Xavier
Advisor: Gakwaya, AugustinGuillot, Michel
Abstract: In the current work, it is shown that an existing helicopter skid landing gear cross tube, made by tube bending and chemical milling, could be replaced by another cross tube, whose innovative shape is producible by tube hydroforming. This method has for example the advantage of being more environmentally friendly than the current manufacturing process, because it does not require the use of hazardous chemicals. In addition, the methodology developed in this project takes into account the cross tube material’s history throughout the manufacturing process. Moreover, the performance of a skid landing gear equipped with this new cross tube has been evaluated numerically. This thesis simulation work has been developed with the finite element analysis software ABAQUS. It highlights the potential gains of using a reliable and accurate solid-shell finite element which is capable to take into account the through-thickness behavior of thin structures with a single layer of elements. A new smoothing technique called «Smoothed finite element method» or «SFEM» has been considered for its simplicity and insensitivity to mesh distortion, sometimes encountered while simulating complex shapes forming. A new resultant linear solid-shell element using this SFEM to deal with membrane and bending kinematics has been developed and successfully tested through classical benchmark problems found in the literature. This new element has often shown much greater level of accuracy than other existing elements. In addition, a novel reduced integration solid-shell element, able to work with most three dimensions constitutive laws even in the presence of thin structures is also discussed. This element, free of locking, shows a good accuracy level with respect to existing elements in implicit geometrically linear and non-linear benchmark problems. Its extension to explicit formulation is coupled with a three dimensions hyper elastoplastic constitutive law and tested in a tube hydroforming simulation involving high pressures, friction and large deformations.
Document Type: Thèse de doctorat
Issue Date: 2013
Open Access Date: 23 April 2018
Grantor: Université Laval
Collection:Thèses et mémoires

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