ABSTRACT
This research reports the results related to the evaluation of the fatigue phenomenon of the arms of a medium-large excavator made of composite material (carbon fiber) instead of the classic constructional steel S355 (UNI EN 10025-3). In the numerical sizing phase, it was obtained that the overall weight of the excavator's arms made of composite material is about 35% of the same components made of steel, obviously with equal performance in terms of the safety static coefficient, rigidity, and critical buckling load. The evaluation of the fatigue behaviour (assuming 5.25 × 106 load cycles) applied for each load condition analyzed (levelling from the maximum distance to the minimum, lifting at the maximum distance, lifting at the minimum distance and rotation) shows the magnitude of the safety coefficients both related to the allowable stress and relative to the number of cycles acceptable. The assumption instead of combined cycles (involving one or more load conditions) leads to a significant reduction in the magnitude of the safety coefficients. The implementation of a loading cycle plan resulting from the different load conditions must be reliably assessed to evaluate as accurately as possible the fatigue behavior of the excavator arms made of composite material.
ABSTRACT
In this research, the design of a new competitive handbike fork, made of a composite material, is presented. The study is based both on an early finite element analysis and on a CFD analysis of the characteristics and performance of a standard fork made of aluminum, allowing to define the loading and the flux conditions and to provide a design optimization of the fork. The model was later implemented iteratively with the properties of a carbon-fiber composite material. The results obtained show that the new model allows a weight and a drag force reduction and a downforce improvement, with a stiffness and a safety coefficient comparable to the standard aluminum fork.
Subject(s)
Aluminum , Carbon Fiber , Prosthesis DesignABSTRACT
This study is a detailed failure analysis of galvanized high carbon steel wires, which developed coating cracks during the torsion test performed as a quality control at the end of the manufacturing process. Careful visual inspections showed that the cracks are already present in the coating before the torsion test. In order to explain the origin of these cracks, systematic metallographic investigations were performed by means of optical and scanning electron microscope on both the wires and the rods that have been cold drawn to produce the wire. The chemical composition of the galvanized coatings was evaluated by means of energy dispersive spectroscopy. Micro bidimensional X-ray diffraction experiments were also performed to measure the residual stresses in the galvanized coating. The results showed that the failure is related to two main factors: the relatively high content of silicon in the steel and the unsuitable cooling rate of the rods at the exit from the galvanizing bath. The mechanism proposed to explain the origin of the defects was supported by Finite Elements Methods simulations and verified with in-plant tests. The proper countermeasures were then applied and the problem successfully solved.
