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Open Access
Article
Publication date: 27 September 2023

Markus Brummer, Karl Jakob Raddatz, Matthias Moritz Schmitt, Georg Schlick, Thomas Tobie, Rüdiger Daub and Karsten Stahl

Numerous metals can be processed using the additive manufacturing process laser-based powder bed fusion of metals (PBF-LB/M, ISO/ASTM 52900). The main advantages of additive…

Abstract

Purpose

Numerous metals can be processed using the additive manufacturing process laser-based powder bed fusion of metals (PBF-LB/M, ISO/ASTM 52900). The main advantages of additive manufacturing technologies are the high degree of design freedom and the cost-effective implementation of lightweight structures. This could be profitable for gears with increased power density, combining reduced mass with considerable material strength. Current research on additively manufactured gears is focused on developing lightweight structures but is seldom accompanied by simulations and even less by mechanical testing. There has been very little research into the mechanical and material properties of additively manufactured gears. The purpose of this study is to investigate the behavior of lightweight structures in additively manufactured gears under static loads.

Design/methodology/approach

This research identifies the static load-carrying capacity of helical gears with different lightweight structures produced by PBF-LB/M with the case hardening steel 16MnCr5. A static gear loading test rig with a maximum torque at the pinion of T1 = 1200 Nm is used. Further focus is set on analyzing material properties such as the relative density, microstructure, hardness depth profile and chemical composition.

Findings

All additively manufactured gear variants show no failure or plastic deformation at the maximum test load. The shaft hub connection, the lightweight hub designs and the gearing itself are stable and intact regarding their form and function. The identified material characteristics are comparable to conventionally manufactured gears (wrought and machined), but also some particularities were observed.

Originality/value

This research demonstrates the mechanical strength of lightweight structures in gears. Future research needs to consider the dynamic load-carrying capacity of additively manufactured gears.

Details

Rapid Prototyping Journal, vol. 29 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 7 September 2023

Nor Salwani Hashim, Fatimah De’nan and Nurfarhah Naaim

Nowadays, residential buildings have become increasingly important due to the growing communities. The purpose of this study is to investigate the behavior of a steel structural…

Abstract

Purpose

Nowadays, residential buildings have become increasingly important due to the growing communities. The purpose of this study is to investigate the behavior of a steel structural framing system that incorporates lightweight load-bearing walls and slabs, and to compare the weight of materials used in cold-formed and hot-finished steel structural systems for affordable housing.

Design/methodology/approach

Four types of models consisting of 243 members were simulated. Model 1 is a cold-formed steel structural framing system, while Model 2 is a hot-finished steel structural framing system. Both Models 1 and 2 use lightweight wall panels and lightweight composite slabs. Models 3 and 4 are made with brick walls and precast reinforced concrete systems, respectively. These structures use different wall and slab materials, namely, brick walls and precast reinforced concrete. The analysis includes bending behavior, buckling resistance, shear resistance and torsional rotation analysis.

Findings

This study found that using thinner steel sections can increase the deflection value. Meanwhile, increasing member length and the ratio of slenderness will decrease buckling resistance. As the applied load increases, buckling deformation also increases. Furthermore, decreasing shear area causes a reduction in shear resistance. Thicker sections and the use of lightweight materials can decrease the torsional rotation value.

Originality/value

The weight comparison of the steel structures shows that Model 1, which is a cold-formed steel structure with lightweight wall panels and lightweight composite slabs, is the most suitable model due to its lightweight and affordability for housing. This model can also be used as a reference for the optimal design of modular structural framing using cold-formed steel materials in the field of civil engineering and as a promotional tool.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 8 September 2022

Yuan Chen, Xiaodong Li, Qi Li and Wenjie Li

Lightweight apps such as WeChat mini programs (WMPs) are an emerging mobile channel (m-channel) touchpoint that have gained remarkable popularity among consumers. Despite the…

Abstract

Purpose

Lightweight apps such as WeChat mini programs (WMPs) are an emerging mobile channel (m-channel) touchpoint that have gained remarkable popularity among consumers. Despite the focus of migration research on traditional m-channel touchpoints (e.g. native apps and mobile websites), but few researchers have examined why consumers switch from native to lightweight apps. Drawing on the push-pull-mooring framework, this study aims to identify the key factors influencing consumers' switching related to lightweight apps.

Design/methodology/approach

The data were collected using a questionnaire survey of 416 WMP consumers and the proposed model was analyzed through structural equation modeling.

Findings

The results show that the push effect, specifically, high privacy concern, nudges consumers away from native apps, whereas the pull effects, including relative ease of use, convenience of access and exit and socially-oriented interaction, entice consumers to lightweight apps. Further, consumer switching intention is influenced by habit and perceived technology control, both of which reflect the mooring effects. Switching intention also stands as an important precedent of actual behavior.

Originality/value

This study is among the first theoretical explorations of consumer switching across m-channel touchpoints in the context of mobile commerce. For information system practice, these findings provide new insights for both incumbent providers and newcomers on how to retain existing shoppers as well as attract potential shoppers effectively.

Details

Industrial Management & Data Systems, vol. 122 no. 12
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 1 August 2022

Di Wang, Xiongmian Wei, Jian Liu, Yunmian Xiao, Yongqiang Yang, Linqing Liu, Chaolin Tan, Xusheng Yang and Changjun Han

This paper aims to explore a structural optimization method to achieve the lightweight design of an aviation control stick part manufactured by laser powder bed fusion (LPBF…

Abstract

Purpose

This paper aims to explore a structural optimization method to achieve the lightweight design of an aviation control stick part manufactured by laser powder bed fusion (LPBF) additive manufacturing (AM). The utilization of LPBF for the fabrication of the part provides great freedom to its structure optimization, further reduces its weight and improves its portability.

Design/methodology/approach

The stress distribution of the model was analyzed by finite element analysis. The material distribution path of the model was optimized through topology optimization. The structure and size of the parts were designed by applying honeycomb structures for weight reduction. The lightweight designed control stick part model was printed by LPBF using AlSi10Mg.

Findings

The weight of the control stick model was reduced by 32.64% through the optimization method using honeycomb structures with various geometries. The similar stress concentrations of the control stick model indicate that weight reduction has negligible effect on its mechanical strength. The maximum stress of the lightweight designed model under loading is 230.85 MPa, which is 61.81% larger than that of the original model. The lightweight control stick part manufactured by LPBF has good printability and service performance.

Originality/value

A structural optimization method integrating topology, shape and size optimization was proposed for a lightweight AlSi10Mg control stick printed by LPBF. The effectiveness of the optimization method, the printability of the lightweight model and the service performance of LPBF-printed AlSi10Mg control stick was verified, which provided practical references for the lightweight design of AM.

Details

Rapid Prototyping Journal, vol. 28 no. 10
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 14 July 2021

Irindu Upasiri, Chaminda Konthesingha, Anura Nanayakkara, Keerthan Poologanathan, Brabha Nagaratnam and Gatheeshgar Perampalam

In this study, the insulation fire ratings of lightweight foamed concrete, autoclaved aerated concrete and lightweight aggregate concrete were investigated using finite element…

216

Abstract

Purpose

In this study, the insulation fire ratings of lightweight foamed concrete, autoclaved aerated concrete and lightweight aggregate concrete were investigated using finite element modelling.

Design/methodology/approach

Lightweight aggregate concrete containing various aggregate types, i.e. expanded slag, pumice, expanded clay and expanded shale were studied under standard fire and hydro–carbon fire situations using validated finite element models. Results were used to derive empirical equations for determining the insulation fire ratings of lightweight concrete wall panels.

Findings

It was observed that autoclaved aerated concrete and foamed lightweight concrete have better insulation fire ratings compared with lightweight aggregate concrete. Depending on the insulation fire rating requirement of 15%–30% of material saving could be achieved when lightweight aggregate concrete wall panels are replaced with the autoclaved aerated or foamed concrete wall panels. Lightweight aggregate concrete fire performance depends on the type of lightweight aggregate. Lightweight concrete with pumice aggregate showed better fire performance among the normal lightweight aggregate concretes. Material saving of 9%–14% could be obtained when pumice aggregate is used as the lightweight aggregate material. Hydrocarbon fire has shown aggressive effect during the first two hours of fire exposure; hence, wall panels with lesser thickness were adversely affected.

Originality/value

Finding of this study could be used to determine the optimum lightweight concrete wall type and the optimum thickness requirement of the wall panels for a required application.

Details

Journal of Structural Fire Engineering, vol. 12 no. 3
Type: Research Article
ISSN: 2040-2317

Keywords

Article
Publication date: 11 June 2021

Jichang Wang and Xiaoming Guo

A mesoscopic phase field (PF) model is proposed to simulate the meso-failure process of lightweight concrete.

318

Abstract

Purpose

A mesoscopic phase field (PF) model is proposed to simulate the meso-failure process of lightweight concrete.

Design/methodology/approach

The PF damage model is applied to the meso-failure process of lightweight concrete through the ABAQUS subroutine user-defined element (UEL). And the improved staggered iteration scheme with a one-pass procedure is used to alternately solve the coupling equations.

Findings

These examples clearly show that the crack initiation of the lightweight concrete specimens mainly occurs in the ceramsite aggregates with weak strength, especially in the larger aggregates. The crack propagation paths of the specimens with the same volume fraction of light aggregates are completely different, but the crack propagation paths all pass through the ceramsite aggregates near the cracks. The results also showed that with the increase in the volume fractions of the aggregates, the slope and the peak loads of the force-deflection (F-d) curves gradually decrease, the load-bearing capacity of the lightweight concrete specimens decreases, and crack branching and coalescence are less likely during crack propagation.

Originality/value

The mesostructures with a mortar matrix, aggregates and an interfacial transition zone (ITZ) are generated by an automatic generation and placement program, thus incorporating the typical three-phase characteristics of lightweight concrete into the PF model.

Details

Engineering Computations, vol. 38 no. 10
Type: Research Article
ISSN: 0264-4401

Keywords

Article
Publication date: 1 April 2021

Md Delwar Hossain, Md Kamrul Hassan, Anthony Chun Yin Yuen, Yaping He, Swapan Saha and Waseem Hittini

The purpose of this study is to review and summarise the existing available literature on lightweight cladding systems to provide detailed information on fire behaviour…

Abstract

Purpose

The purpose of this study is to review and summarise the existing available literature on lightweight cladding systems to provide detailed information on fire behaviour (ignitibility, heat release rate and smoke toxicity) and various test method protocols. Additionally, the paper discusses the challenges and provides updated knowledge and recommendation on selective-fire mechanisms such as rapid-fire spread, air cavity and fire re-entry behaviours due to dripping and melting of lightweight composite claddings.

Design/methodology/approach

A comprehensive literature review on fire behaviour, fire hazard and testing methods of lightweight composite claddings has been conducted in this research. In summarising all possible fire hazards, particular attention is given to the potential impact of toxicity of lightweight cladding fires. In addition, various criteria for fire performance evaluation of lightweight composite claddings are also highlighted. These evaluations are generally categorised as small-, intermediate- and large-scale test methods.

Findings

The major challenges of lightweight claddings are rapid fire spread, smoke production and toxicity and inconsistency in fire testing.

Originality/value

The review highlights the current challenges in cladding fire, smoke toxicity, testing system and regulation to provide some research recommendations to address the identified challenges.

Details

Journal of Structural Fire Engineering, vol. 12 no. 3
Type: Research Article
ISSN: 2040-2317

Keywords

Article
Publication date: 1 June 1995

R.V. Balendran

Discusses the results of a study of the moduli of elasticity ofconcretes made with artificially manufactured lightweight aggregatessubjected to uniaxial compression and uniaxial…

3491

Abstract

Discusses the results of a study of the moduli of elasticity of concretes made with artificially manufactured lightweight aggregates subjected to uniaxial compression and uniaxial tension. Two artificially manufactured lightweight aggregates and one normal weight aggregate (for comparison) were used in the investigation. Concrete mixes designed to have compressive strengths varying from 20 MPa to 60 MPa were used in this study. Presents the results of static and dynamic moduli of elasticity, Poisson′s ratio, ultrasonic pulse velocity, compressive strength and tensile strength tests. Observes that the static modulus of elasticity in tension is nearly equal to the static modulus of elasticity in compression at a stress level of one‐third the ultimate stress. Compressive modulus values are shown to be dependent on the stress level and type of modulus, i.e. either secant or tangent. On the other hand, the tensile modulus is not affected by the stress level. The modulus of elasticity of lightweight aggregate concrete is about 60‐70 per cent of that of normal weight concrete. Compares the test results obtained in this study with research work carried out on other lightweight aggregate concretes by other investigators. Also presents the relationships between static modulus of elasticity, dynamic modulus of elasticity, compressive strength, and Poisson′s ratio, and equations for estimating elastic modulus and Poisson′s ratio.

Details

Structural Survey, vol. 13 no. 2
Type: Research Article
ISSN: 0263-080X

Keywords

Article
Publication date: 1 December 2005

Andrew J. Graettinger, Philip W. Johnson, Pramodh Sunkari, Matthew C. Duke and Jonathan Effinger

Geotechnical fills are used for building roadway embankments, filling in behind retaining walls, and as backfill above buried pipelines. Lightweight fill reduces the load so…

2599

Abstract

Purpose

Geotechnical fills are used for building roadway embankments, filling in behind retaining walls, and as backfill above buried pipelines. Lightweight fill reduces the load so structures can be built more economically. A new lightweight geo‐material made from recycled plastic bottles glued together in their original post‐consumer form was developed. The purpose of this work is to explore the use of this new material as a lightweight geotechnical fill.

Design/methodology/approach

Through a preliminary laboratory and field study, aspects of the physical and mechanical characteristics of the recycled plastic bottle blocks were investigated. This new material is currently undergoing field trials behind a retaining wall on a bicycle path.

Findings

It was found that the average density of this new material is very low, at 32.63 kg/m3 (2.04 lb/ft3), with 59.5 percent of a block made up of recycled plastic bottles. The plastic bottle waste stream obtained from a recycling plant is gap‐graded having approximately 25 percent of the bottle volume at the 2 l bottle size with the remaining 75 percent at the 500 ml bottle size. Unconfined compression tests on small ten‐bottle samples produced strengths of 60 kN/m2 (1,250 lb/ft2).

Practical implications

Testing indicates that this material may be useful as a lightweight geotechnical fill over soft soils or behind retaining walls; as an energy‐absorbing crash barrier for highway, race track, or airport safety; as ground and building insulation for Arctic construction; as floating barriers or platforms for offshore work; or for acoustic or vibration dampening for manufacturing processes.

Originality/value

This work explores the use of large volumes of recycled plastic bottles as an environmentally friendly geotechnical engineering material. Engineering parameters for this new material are presented as well as a discussion of an ongoing field study. The information presented here is the first step in understanding this new material with respect to civil engineering applications.

Details

Management of Environmental Quality: An International Journal, vol. 16 no. 6
Type: Research Article
ISSN: 1477-7835

Keywords

Article
Publication date: 17 January 2022

Irindu Upasiri, Chaminda Konthesingha, Anura Nanayakkara, Keerthan Poologanathan, Gatheeshgar Perampalam and Dilini Perera

Light-Gauge Steel Frame (LSF) structures are popular in building construction due to their lightweight, easy erecting and constructability characteristics. However, due to steel…

Abstract

Purpose

Light-Gauge Steel Frame (LSF) structures are popular in building construction due to their lightweight, easy erecting and constructability characteristics. However, due to steel lipped channel sections negative fire performance, cavity insulation materials are utilized in the LSF configuration to enhance its fire performance. The applicability of lightweight concrete filling as cavity insulation in LSF and its effect on the fire performance of LSF are investigated under realistic design fire exposure, and results are compared with standard fire exposure.

Design/methodology/approach

A Finite Element model (FEM) was developed to simulate the fire performance of Light Gauge Steel Frame (LSF) walls exposed to realistic design fires. The model was developed utilising Abaqus subroutine to incorporate temperature-dependent properties of the material based on the heating and cooling phases of the realistic design fire temperature. The developed model was validated with the available experimental results and incorporated into a parametric study to evaluate the fire performance of conventional LSF walls compared to LSF walls with lightweight concrete filling under standard and realistic fire exposures.

Findings

Novel FEM was developed incorporating temperature and phase (heating and cooling) dependent material properties in simulating the fire performance of structures exposed to realistic design fires. The validated FEM was utilised in the parametric study, and results exhibited that the LSF walls with lightweight concrete have shown better fire performance under insulation and load-bearing criteria in Eurocode parametric fire exposure. Foamed Concrete (FC) of 1,000 kg/m3 density showed best fire performance among lightweight concrete filling, followed by FC of 650 kg/m3 and Autoclaved Aerated Concrete (AAC) 600 kg/m3.

Research limitations/implications

The developed FEM is capable of investigating the insulation and load-bearing fire ratings of LSF walls. However, with the availability of the elevated temperature mechanical properties of the LSF wall, materials developed model could be further extended to simulate the complete fire behaviour.

Practical implications

LSF structures are popular in building construction due to their lightweight, easy erecting and constructability characteristics. However, due to steel-lipped channel sections negative fire performance, cavity insulation materials are utilised in the LSF configuration to enhance its fire performance. The lightweight concrete filling in LSF is a novel idea that could be practically implemented in the construction, which would enhance both fire performance and the mechanical performance of LSF walls.

Originality/value

Limited studies have investigated the fire performance of structural elements exposed to realistic design fires. Numerical models developed in those studies have considered a similar approach as models developed to simulate standard fire exposure. However, due to the heating phase and the cooling phase of the realistic design fires, the numerical model should incorporate both temperature and phase (heating and cooling phase) dependent properties, which was incorporated in this study and validated with the experimental results. Further lightweight concrete filling in LSF is a novel technique in which fire performance was investigated in this study.

Details

Journal of Structural Fire Engineering, vol. 13 no. 4
Type: Research Article
ISSN: 2040-2317

Keywords

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