Capillary forces acting at the interfaces of soft materials lead to deformations over the scale of the elastocapillary length. When surface stresses exceed a material's yield stress, a plastocapillary effect is expected to arise, resulting in yielding and plastic deformation. Here, we explore the interfacial instabilities of 3D-printed fluid and elastic beams embedded within viscoelastic fluids and elastic solid support materials. Interfacial instabilities are driven by the immiscibility between the paired phases or their solvents. We find that the stability of an embedded structure is predicted from the balance between the yield stress of the elastic solid, τ y , the apparent interfacial tension between the materials, γ ′, and the radius of the beam, r , such that τ y > γ ′/ r . When the capillary forces are sufficiently large, we observe yielding and failure of the 3D printed beams. Furthermore, we observe new coiling and buckling instabilities emerging when elastic beams are embedded within viscous fluid support materials. The coiling behavior appear analogous to elastic rope coiling whereas the buckling instability follows the scaling behavior predicted from Euler–Bernoulli beam theory.
more »
« less
This content will become publicly available on September 1, 2025
Cohesive zone modeling of the buckling behavior of a fusion-joined, additive-manufactured wind blade
In this article, the use of additive-manufactured thermoplastics, specifically polylactic acid (PLA), to fabricate segments of wind turbine blades with core sandwich composites was verified through their compressive bucking performance, demonstrating their costeffectivness in manufacturing and transportation. A small wind blade was constructed by joining these segments to demonstrate their application potential in renewable energy technologies. The study’s focus was on the compressive buckling behavior of these fusion joined
blades, particularly on the heterogeneity at the resistance welding bond line. An approach was adopted to integrate a hybrid of solid and cohesive elements within the cohesive zone modeling (CZM) framework using the Abaqus–Riks method. This allowed us to insert a thin layer of solid–cohesive elements at the bond line, enhancing the fidelity of our simulations. The validity of our numerical results was examined by comparing them with the surface strain field measured by digital image correlation (DIC) and assessing the compressive response. Furthermore, the applicability of classical Euler and Johnson formulas was evaluated in predicting buckling loads and modes. The Euler formula was found adequate for the first flexural buckling mode in beams with high slenderness ratios (≥12). Our findings demonstrate that the hybrid CZM approach effectively models the buckling behavior of fusion-joined beams, accommodating a range of slenderness ratios (6 to 18) and various buckling modes. This study provides insights into the structural analysis of fusion-joined components for potential applications of additive manufacturing in wind energy.
more »
« less
- Award ID(s):
- 2219347
- PAR ID:
- 10553071
- Publisher / Repository:
- https://www.academia.edu
- Date Published:
- Journal Name:
- Academia Materials Science
- Volume:
- 1
- Issue:
- 3
- ISSN:
- 2997-2027
- Subject(s) / Keyword(s):
- cohesive zone modeling, green manufacturing, sustainability, thin-walled lattice structure, fusion joining, material extrusion
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
more » « less
Abstract Wind turbine towers are highly slender and made of thin cylindrical shells with large diameter‐to‐thickness ratios, which means stability is an essential concern. The high diameter‐to‐thickness ratios of these cylinders make them highly imperfection sensitive, meaning their failure loads and failure modes are highly dependent on initial geometries. Combined bending and torsion is commonly a controlling load case in the upper tower segments, but this load case has not seen significant study to date. To address the knowledge gap, an experimental study was conducted on the stability of cylinders under combined bending and torsion. A total of 48 cylinders were tested with varying diameter‐to‐thickness ratios and bending‐to‐torsion combinations seen in wind turbine towers. To better understand how imperfections affect the buckling modes of these thin‐walled cylinders, a 3D laser scanner was used to determine geometric imperfections of each test specimen prior to testing. This paper details the test setup and results of the experiments.
-
Thin (slender) steel plates possess shear strength beyond the elastic buckling load which is commonly referred to as the post-buckling capacity. Semi-empirical equations based on experimental tests of plate girders have been used for decades to predict the ultimate post-buckling strength of slender webs. However, several recent studies have shown that the current models for predicting the ultimate shear post-buckling capacity of thin plates are based on some incorrect assumptions regarding their mechanical behavior. As a result, the current design equations provide an approximate estimate of capacity for the range of parameters in the test data upon which they are founded. This paper explores the fundamental behavior of thin plates under pure shear. Such a fundamental examination of shear post-buckling behavior in thin plates is needed to enable design procedures that can optimize a plate’s shear strength and load-deformation performance for a wider range of loading and design parameters. Using finite element analyses, which are validated against available results of previous experimental tests, outputs such as plastic strains, von Mises stresses, principal stresses, and principal stress directions are examined on a buckled plate acting in pure shear. The internal bending, shear, and membrane stresses in the plate’s finite elements are also evaluated. In this study, these evaluations are performed for a simply-supported plate with an aspect ratio equal to 1.0 and slenderness ratio equal to 134. Results show that localized bending in the plates due to the out-of-plane post-buckling deformations appear to be a significant factor in the ultimate shear post-buckling capacity of the plate. Also, the compressive stresses continue to increase beyond the onset of elastic buckling in some regions of the plate, contrary to current design assumptions. Overall, this study provides new insights into the mechanics of shear post-buckling behavior of thin plates that can be exploited for design procedures that are consistent with mechanical behavior.more » « less
-
more » « less
Abstract Tailoring thermal transport by structural parameters could result in mechanically fragile and brittle networks. An indispensable goal is to design hierarchical architecture materials that combine thermal and mechanical properties in a continuous and cohesive network. A promising strategy to create such a hierarchical network targets additive manufacturing of hybrid porous voxels at nanoscale. Here we describe the convergence of agile additive manufacturing of porous hybrid voxels to tailor hierarchically and mechanically tunable objects. In one strategy, the uniformly distributed porous silica voxels, which form the basis for the control of thermal transport, are non-covalently interfaced with polymeric networks, yielding hierarchic super-elastic architectures with thermal insulation properties. Another additive strategy for achieving mechanical strength involves the versatile orthogonal surface hybridization of porous silica voxels retains its low thermal conductivity of 19.1 mW m−1 K−1, flexible compressive recovery strain (85%), and tailored mechanical strength from 71.6 kPa to 1.5 MPa. The printed lightweight high-fidelity objects promise thermal aging mitigation for lithium-ion batteries, providing a thermal management pathway using 3D printed silica objects.
-
The ability of biomolecules to exert forces on their surroundings or resist compression from the environment is essential in a variety of biologically relevant contexts. For filaments in the low-temperature limit and under a constant compressive force, Euler buckling theory predicts a sudden transition from a compressed state to a bent state in these slender rods. In this paper, we use a mean-field theory to show that if a semiflexible chain is compressed at a finite temperature with a fixed end-to-end distance (permitting fluctuations in the compressive forces), it exhibits a continuous phase transition to a buckled state at a critical level of compression. We determine a quantitatively accurate prediction of the transverse position distribution function of the midpoint of the chain that indicates this transition. We find that the mean compressive forces are non-monotonic as the extension of the filament varies, consistent with the observation that strongly buckled filaments are less able to bear an external load. We also find that for the fixed extension (isometric) ensemble, the buckling transition does not coincide with the local minimum of the mean force (in contrast to Euler buckling). We also show that the theory is highly sensitive to fluctuations in length in two dimensions and the buckling transition can still be accurately recovered by accounting for those fluctuations. These predictions may be useful in understanding the behavior of filamentous biomolecules compressed by fluctuating forces, relevant in a variety of biological contexts.more » « less
