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The purpose of this paper is to derive knockdown factor functions in terms of a shell thickness ratio (i.e. the ratio of radius to thickness) for conventional orthogrid and hybrid-grid stiffened cylinders for the lightweight design of space launch vehicles.

The shell knockdown factors of grid-stiffened cylinders under axial compressive loads are derived numerically considering various shell thickness ratios. Two grid systems using stiffeners – conventional orthogrid and hybrid-grid systems – are used for the grid-stiffened cylinders. The hybrid-grid stiffened cylinder uses major and minor stiffeners having two different cross-sectional areas. For modeling grid-stiffened cylinders with various thickness ratios, the effective thickness (t_eff) of the cylinders is kept constant, and the radius of the cylinder is varied. Thickness ratios of 100, 192 and 300 are considered for the orthogrid stiffened cylinder, and 100, 160, 200 and 300 for the hybrid-grid stiffened cylinder. Postbuckling analyses of grid-stiffened cylinders are conducted using a commercial nonlinear finite element analysis code, ABAQUS, to derive the shell knockdown factor. The single perturbation load approach is applied to represent the geometrical initial imperfection of a cylinder. Knockdown factors are derived for both the conventional orthogrid and hybrid-grid stiffened cylinders for different shell thickness ratios. Knockdown factor functions in terms of shell thickness ratio are obtained by curve fitting with the derived shell knockdown factors for the two grid-stiffened cylinders.

For the two grid-stiffened cylinders, the derived shell knockdown factors are all higher than the previous NASA’s shell knockdown factors for various shell thickness ratios, ranging from 100 to 400. Therefore, the shell knockdown factors derived in this study may facilitate in the development of lightweight structures of space launch vehicles from the aspect of buckling design. For different shell thickness ratios of up to 500, the knockdown factor of the hybrid-grid stiffened cylinder is higher than that of the conventional orthogrid stiffened cylinder. Therefore, it is concluded that the hybrid-grid stiffened cylinder is more efficient than the conventional orthogrid-stiffened cylinder from the perspective of buckling design.

The obtained knockdown factor functions may provide the design criteria for lightweight cylindrical structures of space launch vehicles.

Derivation of shell knockdown factors of hybrid-grid stiffened cylinders considering various shell thickness ratios is attempted for the first time in this study.

Integrity assessment is used to ensure reliability operation of a pressurized equipment containing defects. Based on data of cylindrical shell dimensions, operation conditions, material properties and crack dimensions, an assessment can be carried out, using either Level 1, Level 2 or Level 3 procedure. Assessment using Level 3 procedure within the code requires a finite element simulation in order to generate both the evaluation point and the failure assessment diagram (FAD) that serves as the acceptance criteria. The purpose of this paper is to provide the numerical data which are used for integrity assessment of a pressure vessel containing crack. Here, a parametric study has been carried out to generate such result for the cases of longitudinal crack defect in a cylindrical shell for a number of common cases, in terms of thickness-to-radius ratio, crack size ratio and crack aspect ratio.

The evaluation of stress intensity factor is determined through J-integral parameter found using a finite element analysis with a specially meshed strategy incorporating the crack. A comparison is made against stress intensity factor provided by the code.

A good agreement is obtained with percent error of 2.13 percent for low aspect ratio crack, and 0.57 percent for high aspect ratio crack. Furthermore, a study has been carried out using the methodology for 160 cases, covering both cases already available in the code and other cases of crack in cylindrical shells. The result can be used as a complement to the existing tabular data available in the code for Level 2 assessment, to be used for integrity analysis of damaged cylindrical shells based on the FAD criteria.

The result can be used as a complement to the existing tabular data available in the API 579 code for Level 2 assessment, to be used for integrity analysis of damaged cylindrical shells based on the FAD criteria. New equations were generated based on finite element analysis and can be used for Level 3 assessment of the code.

While additive manufacturing via melt-extrusion of plastics has been around for more than several decades, its application to complex geometries has been hampered by the discretization of parts into planar layers. This requires wasted support material and introduces anisotropic weaknesses due to poor layer-to-layer adhesion. Curved-layer manufacturing has been gaining attention recently, with increasing potential to fabricate complex, low-weight structures, such as mechanical metamaterials. This paper aims to study the fabrication and mechanical characterization of non-planar lattice structures under cyclic loading.

A mathematical approach to parametrize lattices onto Bèzier surfaces is validated and applied here to fabricate non-planar lattice samples via curved-layer fused deposition modeling. The lattice chirality, amplitude and unit cell size were varied, and the properties of the samples under cyclic-loading were studied experimentally.

Overall, lattices with higher auxeticity showed less energy dissipation, attributed to their bending-deformation mechanism. Additionally, bistability was eliminated with increasing auxeticity, reinforcing the conclusion of bending-dominated behavior. The analysis presented here demonstrates that mechanical metamaterial lattices such as auxetics can be explored experimentally for complex geometries where traditional methods of comparing simple geometry to end-use designs are not applicable.

The mechanics of non-planar lattice structures fabricated using curved-layer additive manufacturing have not been studied thoroughly. Furthermore, traditional approaches do not apply due to parameterization deformations, requiring novel approaches to their study. Here the properties of such structures under cyclic-loading are studied experimentally for the first time. Applications for this type of structures can be found in areas like biomedical scaffolds and stents, sandwich-panel packaging, aerospace structures and architecture of lattice domes.

This work presents an experimental approach to study the mechanical properties of non-planar lattice structures via quasi-static cyclic loading, comparing variations across several lattice patterns including auxetic sinusoids, disrupted sinusoids and their equivalent-density quadratic patterns.

The purpose of this paper is to present some modifications in the spline‐based differential quadrature method (DQM), in order to accelerate the convergence of the method. The improvements are explained and examined by the examples of the free vibration of conical shells. The composite laminated shell, as well as isotropic one, are taken under consideration.

To determine weighting coefficients for the DQM, the spline interpolation with non‐standard definitions of the end conditions is used. One of these definitions combines natural and not‐a‐knot end conditions, while the other one uses the boundary conditions for considered problem as the end conditions. The weighting coefficients can be determined by solving set of equations arising from spline interpolation.

It is shown that the proposed modifications significantly improve the convergence of the method, especially when the boundary conditions are introduced at the stage of the computation of the weighting coefficients. Unfortunately, the use of this approach is limited to some types of boundary conditions.

The paper describes development of the modified spline interpolation dedicated to DQM and examines the possibility of building boundary conditions into the weighting coefficients at the stage of the computation of these coefficients.

The optimization of variable thickness plates and shells is studied. In particular, three types of shell are considered: hyperbolic paraboloid, conoid and cylindrical shell. The main objective is to investigate the optimal thickness distributions as the geometric form of the structure changes from a plate to a deep shell. The optimal thickness distribution is found by use of a structural optimization algorithm which integrates the Coons patch technique for thickness definition, structural analysis using 9‐node Huang‐Hinton shell elements, sensitivity evaluation using the global finite difference method and the sequential quadratic programming method. The composition of the strain energy is monitored during the optimization process to obtain insight into the energy distribution for the optimum structures. Several benchmark examples are considered illustrating optimal thickness variations under different loading, boundary and design variable linking conditions.

To investigate the large amplitude free flexural vibration of doubly curved shallow shells in the presence of cutouts.

Finite element model using an eight‐noded C⁰ continuity, isoparametric quadrilateral element is employed. Nonlinear strains of von Karman type are incorporated into the first‐order shear deformation theory.

Cylindrical shell shows mostly hard spring behavior whereas spherical shell shows both hard spring and soft spring behavior with the increase of amplitude ratios for different cutout sizes, radii of curvature and thickness parameters. At a particular value of the amplitude ratio, the frequency ratio of shells is governed by the interactive effects of stiffness and mass.

Aircraft, spacecraft and many other structures where shell panels are used, undergo large amplitude nonlinear vibrations.

The paper will assist researchers of vibration behavior of elastic systems.

This study aims to provide a reliable and effective algorithm that is suitable for addressing the problems of continuous orders of frequencies and modes under different boundary conditions, circumferential wave numbers and thickness-to-length ratios of moderately thick circular cylindrical shells. The theory of free vibration of rotating cylindrical shells is of utmost importance in fields such as structural engineering, rock engineering and aerospace engineering. The finite element method is commonly used to study the theory of free vibration of rotating cylindrical shells. The proposed adaptive finite element method can achieve a considerably more reliable high-precision solution than the conventional finite element method.

On a given finite element mesh, the solutions of the frequency mode of the moderately thick circular cylindrical shell were obtained using the conventional finite element method. Subsequently, the superconvergent patch recovery displacement method and high-order shape function interpolation techniques were introduced to obtain the superconvergent solution of the mode (displacement), while the superconvergent solution of the frequency was obtained using the Rayleigh quotient computation. Finally, the superconvergent solution of the mode was used to estimate the errors of the finite element solutions in the energy norm, and the mesh was subdivided to generate a new mesh in accordance with the errors.

In this study, a high-precision and reliable superconvergent patch recovery solution for the vibration modes of variable geometrical rotating cylindrical shells was developed. Compared with conventional finite element method, under the challenging varying geometrical circumferential wave numbers, and thickness–length ratios, the optimised finite element meshes and high-precision solutions satisfying the preset error limits were obtained successfully to solve the frequency and mode of continuous orders of rotating cylindrical shells with multiple boundary conditions such as simple and fixed supports, demonstrating good solution efficiency. The existing problem on the difficulty of adapting a set of meshes to the changes in vibration modes of different orders is finally overcome by applying the adaptive optimisation.

The approach developed in this study can accurately obtain the superconvergent patch recovery solution of the vibration mode of rotating cylindrical shells. It can potentially be extended to fine numerical models and high-precision computations of vibration modes (displacement field) and solid stress (displacement derivative field) for general structural special value problems, which can be extensively applied in the field of engineering computations in the future. Furthermore, the proposed method has the potential for adaptive analyses of shell structures and three-dimensional structures with crack damage. Compared with conventional finite element methods, significant advantages can be achieved by solving the eigenvalues of structures with high precision and stability.

This paper deals with structural shape and thickness optimization of axisymmetric shell structures loaded symmetrically. In the finite element stress analysis use is made of newly developed linear, quadratic, and cubic, variable thickness, C(0) elements based on axisymmetric Mindlin‐Reissner shell theory. An integrated approach is used to carry out the whole shape optimization process in a fully automatic manner. A robust, versatile and flexible mesh generator is incorporated with facilities for generating either uniform or graded meshes, with constant, linear, or cubic variation of thickness, pressure etc. The midsurface geometry and thickness variations of the axisymmetric shell structure are defined using cubic splines passing through certain key points. The design variables are chosen as the coordinates and/or the thickness at the key points. Variable linking procedures are also included. Sensitivity analysis is carried out using either a semi‐analytical method or a global finite difference method. The objective of the optimization is the weight minimization of the structure. Several examples are presented illustrating optimal shapes and thickness distributions for various shells. The changes in the bending, membrane and shear strain energies during the optimization process are also monitored.

This study presents a novel hp-version adaptive finite element method (FEM) to investigate the high-precision eigensolutions of the free vibration of moderately thick circular cylindrical shells, involving the issues of variable geometrical factors, such as the thickness, circumferential wave number, radius and length.

An hp-version adaptive finite element (FE) algorithm is proposed for determining the eigensolutions of the free vibration of moderately thick circular cylindrical shells via error homogenisation and higher-order interpolation. This algorithm first develops the established h-version mesh refinement method for detecting the non-uniform distributed optimised meshes, where the error estimation and element subdivision approaches based on the superconvergent patch recovery displacement method are introduced to obtain high-precision solutions. The errors in the vibration mode solutions in the global space domain are homogenised and approximately the same. Subsequently, on the refined meshes, the algorithm uses higher-order shape functions for the interpolation of trial displacement functions to reduce the errors quickly, until the solution meets a pre-specified error tolerance condition. In this algorithm, the non-uniform mesh generation and higher-order interpolation of shape functions are suitable for addressing the problem of complex frequencies and modes caused by variable structural geometries.

Numerical results are presented for moderately thick circular cylindrical shells with different geometrical factors (circumferential wave number, thickness-to-radius ratio, thickness-to-length ratio) to demonstrate the effectiveness, accuracy and reliability of the proposed method. The hp-version refinement uses fewer optimised meshes than h-version mesh refinement, and only one-step interpolation of the higher-order shape function yields the eigensolutions satisfying the accuracy requirement.

The proposed combination of methodologies provides a complete hp-version adaptive FEM for analysing the free vibration of moderately thick circular cylindrical shells. This algorithm can be extended to general eigenproblems and geometric forms of structures to solve for the frequency and mode quickly and efficiently.

The purpose of this paper is to investigate experimentally the effect of volume of casting, pouring temperature of different materials and shell mould wall thickness on the surface roughness of the castings obtained by using ZCast direct metal casting process.

Taguchi's design of experiment approach was used for this investigation. An L9 orthogonal array (OA) of Taguchi design which involves nine experiments for three factors with three levels was used. Analysis of variance (ANOVA) was then performed on S/N (signal‐to‐noise) ratios to determine the statistical significance and contribution of each factor on the surface roughness of the castings. The castings were obtained using the shell moulds fabricated with the ZCast process and the surface roughness of castings was measured by using the surface roughness tester.

Taguchi's analysis results showed that pouring temperature of materials was the most significant factor in deciding the surface roughness of the castings and the shell mould wall thickness was the next most significant factor, whereas volume of casting was found insignificant. Confirmation test was also carried out using the optimal values of factor levels to confirm the effectiveness of this approach. The predicted optimal value of surface roughness of castings produced by ZCast process was 6.47 microns.

The paper presents experimentally investigated data regarding the influence of various control factors on the surface roughness of castings produced by using ZCast process. The data may help to enhance the application of ZCast process in traditional foundry practice.