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This paper aims to propose an automatic and direct method to manipulate global parameters of the object for prototyping and simulation, given an STL mesh model of a thin-walled object. Proposed method is useful in rapid prototyping, where changing the global parameters such as thickness, scaling local features or draft of walls of an STL mesh is often required. Presently, user needs to iterate over the cycle of modification of the computer-aided design (CAD) model and tessellating it to change the global parameters. The proposed algorithm eliminates the need for CAD model while manipulating those global properties, as it works directly with the mesh model.

Proposed algorithm automatically identifies walls and its thickness, and then, it extracts mid-surface from each wall. Global parameters are then modified by using these mid-surfaces.

Mesh directly modified and the mesh obtained by tessellating modified CAD model has same global properties; proposed method can also allow multiple parameters to be modified at the same time.

Input STL model is assumed to be error-free, where models containing errors like self-intersection will lead to incorrect mid-surfaces. Present algorithm assumes that the mid-surface represent of the input STL model is a manifold surface.

A novel algorithm of directly manipulating global parameters of a thin-walled object in its STL mesh model is proposed. The paper also presents a novel method of extracting mid-surface representation from a thin-wall STL mesh.

Aims to address the issues pertaining to dynamics of constrained finite rotations as a follow‐up from previous considerations in statics.

A conceptual approach is taken.

In this work the corresponding version of the Newmark time‐stepping schemes for the dynamics of smooth shells employing constrained finite rotations is developed. Different possibilities to choose the constrained rotation parameters are discussed, with the special attention given to the preferred choice of the incremental rotation vector.

The pertinent details of consistent linearization, rotation updates and illustrative numerical simulations are supplied.

The purpose of this paper is to provide an axisymmetric model of tube hydroforming using a Fourier Series based finite element method.

Fourier series interpolation function, which considerably reduces the size of the global stiffness matrix and the number of variables, is employed to approximate displacements. The material of the tube is assumed to be elastic‐plastic and to satisfy the plasticity model that takes into account the rate independent work hardening and normal anisotropy. Numerical solution obtained from an updated Lagrangian formulation of the general shell theory is employed. The axial displacement stroke (a.k.a. axial feed) during tube hydroforming is incorporated using Lagrange multipliers. Contact constraints and boundary friction condition are introduced into the formulation based on the penalty function, which imposes the constraints directly into the tangent stiffness matrix. A forming limit curve based on shear instability and experimental measurements are used as fracture criteria.

The results obtained from this new formulation are compared against the nonlinear finite element code ABAQUS and experimental measurements for isotropic and transversely anisotropic tube materials. The hoop and axial strains predicted with AXHD code compared excellently with those from ABAQUS FEM code using plane stress axisymmetric (SAX1) and four‐node shell (S4R) elements. However, in the case of aluminum, the numerically predicted maximum hoop strain underestimated the actual hoop strain measured from the tube bulging experiment.

The axisymmetric hydroforming program (AXHD) developed in this work is very efficient in simulating the free‐forming stage of the tube hydroforming process under simultaneous action of internal pressurization and displacement stroke.

Although Fourier Series based finite element method has been used in metal forming, the extended application presented in this paper is novel in the finite element analysis of tube hydroforming.

The purpose of this paper is to present a new multilayer process for three‐dimensional molded interconnect devices (3D‐MIDs) that allows the assembly of modern area array packaged semiconductors.

A new 3D‐MID multilayer process based on local overmolding is developed. To investigate this new process, a 3D demonstrator is designed, simulated and fabricated. Various technologies such as injection molding, maskless laser assisted electroless metallization, overmolding and laser via drilling are used.

Using the new 3D‐MID multilayer process a 3D demonstrator with three metallization layers is fabricated. Injection molding simulation is utilized to ensure a feasible demonstrator design. It is shown that a surface laser treatment improves layer‐to‐layer adhesion during the process. Shear and pull tests prove the adhesion promotion. The 3D fine‐pitch‐metallization is done down to 60 μm track width. Via resistance is measured by four terminal sensing in agreement with previous results. Design rules for process compatible vias are introduced. The fabricated demonstrator is suitable for flip‐chip‐based area array packaged semiconductors.

A proof of concept is given by the fabricated demonstrator. Further, work should include reliability tests of the multilayer structures and improvement of individual process steps.

The paper describes a new multilayer process for 3D‐MIDs. It overcomes existing restrictions regarding the electrical routing on 3D‐MID surfaces. The compatibility of area array packaged semiconductors with a high‐inputs/outputs count and the 3D‐MID technology is improved.

This paper is concerned with the performance of shell finite elements, well established in locking‐free computations with linear constitutive laws, in the case of non‐linear elastic material behaviour. Specifically enhanced strain elements are focused on. It is shown that the element behaviour depends on the resulting form of the stress tensor. Phenomenological models for highly non‐linear and elastically deforming rubber, like that of Odgen, are compared with the statistical‐based constitutive model developed by Arruda and Boyce. Whereas computations with the Odgen or any equivalent phenomenological model prove unstable, the behaviour of the enhanced elements, when the statistical model is applied, is shown to be superior. The behaviour is attributed to the mathematical form of the resulting stress tensor.

The purpose of this paper was to construct lubrication model closer to the fact of thrust bearings and to calculate the bearings characteristics of lubrication for understanding how structures influence bearings performances and, importantly, what can be the most beneficial. Large-scale composite thrust bearings with Polytetrafluoroethylene (PTFE)-faced sector pad backed by steel base are used increasingly in equipment. But there are plenty of puzzled problems in design and application.

The authors established a 3D thermal elastohydrodynamic lubrication (TEHL) model. Oil film was formulated by Reynolds equation for pressure, and by energy equation for temperature varying through oil film thickness. Meanwhile, pad temperature was formulated by solid heat transfer equation. Elastic and thermal deformations of pad surface were calculated. Viscosity and density of oil were valued separately under different pressure and temperature. Load balance was considered as well as overturning moment balance. Finite difference method was applied to discrete these equations.

PTFE layer and steel base have either helpful or detrimental impact on contact strength and full film lubrication of thrust bearing depending on their relationship in thickness. Temperature lag between middle layer of steel base and pad surface depends on PTFE layer, but not on the steel base. PTFE layer thickness should be considered when alarming threshold value of the bearings temperature is chosen.

Three-dimensional TEHL model of large-scale composite thrust bearings was established, which included more factors close to the actual. Conclusions were drawn. These proposals are helpful to design the bearings.

The objective of this work is to develop an element technology to recover the plane stress response without any plane stress specific modifications in the large strain regime. Therefore, the essential feature of the proposed element formulation is an interface to arbitrary three‐dimensional constitutive laws. The easily implemented and computational cheap four‐noded element is characterized by coarse mesh accuracy and the satisfaction of the plane stress constraint in a weak sense. A number of example problems involving arbitrary small and large strain constitutive models demonstrate the excellent performance of the concept pursued in this work.

Thin conducting sheets are used in many electric and electronic devices. Solving numerically the eddy current problems in presence of these thin conductive sheets requires a very fine mesh which leads to a large system of equations, and it becomes more problematic in case of higher frequencies. The purpose of this paper is to show the numerical pertinence of equivalent models for 3D eddy current problems with a conductive thin layer of small thickness e based on the replacement of the thin layer by its mid-surface with equivalent transmission conditions that satisfy the shielding purpose, and by using an efficient discretization using the boundary element method (BEM) to reduce the computational work.

These models are solved numerically using the BEM and some numerical experiments are performed to assess the accuracy of the proposed models. The results are validated by comparison with an analytical solution and a numerical solution by the commercial software Comsol.

The error between the equivalent models and analytical and numerical solutions confirms the theoretical approach. In addition to this accuracy, the computational work is reduced by considering a discretization method that requires only a surface mesh.

Based on a hybrid formulation, the authors present briefly a formal derivation of impedance transmission conditions for 3D thin layers in eddy current problems where non-conductive materials are considered in the interior and the exterior domain of the sheet. BEM is adopted to discretize the problem as there is no need for volume discretization.

The purpose of this paper is to deal with large deformation analysis of plane beams composed of functionally graded (FG) elastic material with a variable Poisson’s ratio.

The material is assumed to be linear elastic, with a Poisson’s ratio varying according to a power law along the thickness direction. The finite element used is a plane beam of any-order of approximation along the axis, and with four transverse enrichment schemes, which can describe constant, linear, quadratic and cubic variation of the strain along the thickness direction. Regarding the constitutive law, five materials are adopted: two homogeneous limiting cases, and three intermediate FG cases. The effect of both finite element kinematics and distribution of Poisson’s ratio on the mechanical response of a cantilever is investigated.

In accordance with the scientific literature, the second scheme, in which the transverse strain is linearly variable, is sufficient for homogeneous long (or thin) beams under bending. However, for FG short (or moderate thick) beams, the third scheme, in which the transverse strain variation is quadratic, is needed for a reliable strain or stress distribution.

In the scientific literature, there are several studies regarding nonlinear analysis of functionally graded materials (FGMs) via finite elements, analysis of FGMs with constant Poisson’s ratio, and geometrically linear problems with gradually variable Poisson’s ratio. However, very few deal with finite element analysis of flexible beams with gradually variable Poisson’s ratio. In the present study, a reliable formulation for such beams is presented.

Current commercial rapid prototyping systems can be used for fabricating layered models for subsequent creation of fully‐dense metal parts using investment casting. Due to increased demand for shortened product development cycles however, there exists a demand to rapidly fabricate functional fully‐dense metal parts without hard tooling. A possible solution to this problem is direct layered rapid manufacturing of such parts, for example, via laser‐beam fusion of the metal powder. The rapid manufacturing process discussed herein is based on this approach. It involves selective laser‐beam scanning of a predeposited metal‐powder layer, forming fully‐dense claddings as the basic building block of individual layers. This paper specifically addresses only one of the fundamental issues of the rapid manufacturing process under investigation at the University of Toronto, namely the fabrication of single claddings. Our theoretical investigation of the influence of the process parameters on cladding’s geometrical properties employed thermal modeling and computer process simulation. Numerous experiments, involving fabrication of single claddings, were also carried out with varying process parameters. Comparisons of the process simulations and experimental results showed good agreement in terms of overall trends.