Computer-Aided Supporting Models of Customized Crack Propagation Sensors for Analysis and Prototyping

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Computer-Aided Engineering (CAE)

Background:

• Increasing demand for structural health monitoring (SHM) drives the expansion of sensor technologies.
• Existing crack gauges lack the enhanced functional features and customizability required for advanced SHM.
• Need for efficient methods for rapid prototyping and analysis of novel sensor designs.

Purpose of the Study:

• To introduce a novel Customized Crack Propagation Sensor (CCPS) as an advanced alternative to traditional crack gauges.
• To develop a suite of computer-aided supporting models for the rapid design, prototyping, and analysis of CCPS.
• To present simulation-based methodologies for evaluating the electromechanical and mechanical characteristics of custom CCPS configurations.

Main Methods:

• Development of a LabVIEW-based algorithm for generating sensor layout spreadsheets compatible with Autodesk Inventor and COMSOL Multiphysics.
• Parametric modeling in Autodesk Inventor for automated geometric adjustments based on user-defined data.
• Electromechanical and mechanical analysis using COMSOL Multiphysics and Abaqus, respectively, with a user-friendly GUI for simplified operation.
• Parallel utilization of multiple CAE tools to leverage the strengths of individual software environments.

Main Results:

• Successful generation of tailored CCPS layouts through the developed algorithm and parametric modeling.
• Simulation results indicate negligible strain differences in thin epoxy resin layers (<0.3 mm) during tensile tests.
• Bending tests revealed approximately a 17% change in principal strain across the epoxy resin layer's thickness.
• Demonstrated the capability of the developed GUI to facilitate advanced mechanical analysis for users inexperienced with Abaqus.

Conclusions:

• The developed computer-aided tools enable efficient rapid prototyping and analysis of Customized Crack Propagation Sensors.
• The CCPS offers enhanced functional features and customizability for structural health monitoring applications.
• The integrated simulation approach allows for comprehensive evaluation of sensor performance under various conditions, supporting further research and development.