Failure load prediction and optimisation for adhesively bonded joints enabled by deep learning and fruit fly optimisation

Adhesively bonded joints have been extensively employed in the aeronautical and automotive industries to join thin-layer materials for developing lightweight components. To strengthen the structural integrity of joints, it is critical to estimate and improve joint failure loads effectually. To accomplish the aforementioned purpose, this paper presents a novel deep neural network (DNN) model-enabled approach, and a single lap joint (SLJ) design is used to support research development and validation. The approach is innovative in the following aspects: (i) the DNN model is reinforced with a transfer learning (TL) mechanism to realise an adaptive prediction on a new SLJ design, and the requirement to re-create new training samples and re-train the DNN model from scratch for the design can be alleviated; (ii) a fruit fly optimisation (FFO) algorithm featured with the parallel computing capability is incorporated into the approach to efficiently optimise joint parameters based on joint failure load predictions. Case studies were developed to validate the effectiveness of the approach. Experimental results demonstrate that, with this approach, the number of datasets and the computational time required to re-train the DNN model for a new SLJ design were significantly reduced by 92.00% and 99.57% respectively, and the joint failure load was substantially increased by 9.96%.     

Failure behavior of horseshoe-shaped tunnel in hard rock under high stress: Phenomenon and mechanisms

A particle flow code (PFC) was first applied to examining the mechanical response of a horseshoe-shaped opening in prismatic rock models under biaxial compression. Next, an improved complex variable method was proposed to derive the stress distribution around the opening. Lastly, a case study of tunnel failure caused by rock burst in Jinping II Hydropower Station was further analyzed and discussed. The results manifest that a total of four types of cracks occur around the opening under low lateral confining stress, namely, the primary-tensile cracks on the roof-floor, sidewall cracks on the sidewalls, secondary-tensile cracks on the corners and shear cracks along the diagonals. As the confining stress increases, the tensile cracks gradually disappear whilst the spalling failure becomes severe. Overall, the failure phenomenon of the modelled tunnel agrees well with that of the practical headrace tunnel, and the crack initiation mechanisms can be clearly clarified by the analytical stress distribution.     

Shear crack growth in brittle materials modeled by constrained Cosserat elasticity

The propagation of in-plane shear cracks is investigated in brittle microstructured materials modeled by the constrained Cosserat elasticity. This theory introduces characteristic material lengths in order to describe the scale effects that emerge from the underlying microstructure and has proved to be very effective for modeling complex microstructured materials. An exact solution is obtained based on integral transforms and the Wiener-Hopf technique. Numerical results are presented illustrating the dependence of the stress intensity factor and the energy release rate upon the loading profile, the propagation velocity, and the characteristic material lengths of Cosserat elasticity. It is shown that depending on the Cosserat microstructural lengths the limiting crack propagation velocity can be significantly lower than the classical Rayleigh limit. Moreover, strengthening effects are observed when the characteristic material lengths become comparable to the geometrical lengths of the problem, a behavior that has been experimentally verified in fracture of ceramics.     

A method for testing the interface toughness of ceramic environmental barrier coatings (EBCs) on ceramic matrix composites (CMCs)

A simple interface fracture test for ceramic environmental barrier coatings (EBCs) on ceramic matrix composites (CMCs) was developed. A variation on the asymmetric double cantilever beam (ADCB) test was proposed so that the interface toughness could be measured in a small specimen of simple shape without applying interlaminar loading to the CMC substrate. The proposed test was applied to an EBC consisting of a mullite layer and Si bond coat on a monolithic SiC substrate. A pre-crack was introduced by pop-in cracking, and then a notch overlapping the pre-crack was machined. The pre-crack was opened by inserting a wedge into the notch. From the critical notch opening displacement the crack starts to propagate, interface toughness is calculated. The measured interface toughness was 4.1?J/m2. Finally, the application range of the test was discussed and suggestions were made for introduction of the notch and pre-crack.     

不同应力状态下的高强钢板断裂机理及预测

板料成形过程的宏观断裂行为依赖于其微观断裂机理，因此成形过程模拟中的断裂准则的准确选择对于断裂预测具有重要意义。以高强钢TRIP780板料为研究对象，设计从剪切到拉伸应力状态的五种断裂试验，结合宏观拉伸试验和扫描电子显微镜（Scanning electron microscope，SEM）分析研究不同应力状态下TRIP780板料的断裂机理，得到不同应力状态下正应力和切应力与断裂机理的关联关系，引入正应力与切应力的影响构建MMC断裂准则，应用于板料压剪应力区间的断裂行为预测。结果表明，反映断裂机理的MMC准则能适用于板料压剪和拉剪变形应力状态下断裂失效的准确预测。     

某轻型载货车储气罐支架振动断裂分析与优化

为了有效解决某轻型载货车储气罐支架的断裂故障,首先基于建立的储气罐支架有限元模型进行振动特性分析,分析结果表明其前三阶固有频率接均处于发动机激励频率范围之外,不会产生共振。其次测试各种道路的时域载荷,测试结果表明其中角度搓板路的激励频率与储气罐支架第一阶固有频率相接近,从而引起共振,不满足振动特性要求。然后对其进行振动强度分析,分析结果表明其应力水平不达标,其最大应力点与开裂处一致。再对其进行振动疲劳寿命预测分析,分析结果表明其疲劳寿命也不达标,其危险点也与失效位置相同。再采用集成平台对储气罐支架的结构进行优化设计,优化之后其模态频率、振动强度和振动疲劳均符合性能要求,并且其重量也有所减轻,总体优化效果较佳。最后整车试验结果表明优化之后储气罐支架的振动大幅度降低,并且没有发生失效。     

500 kV输电线路耐张线夹钢锚断裂分析

采用宏观检查、化学成分分析、力学性能测试、显微组织观察等方法分析了某500 kV线路耐张线夹钢锚断裂的原因。结果表明, 钢锚断裂的原因主要是压接工艺控制不当, 在第一模部位产生了应力集中;钢锚压接后加工硬化效应明显, 相较压接前钢锚硬度提高了72%, 达到了210HB, 室温冲击韧性降低了58%, 为31 J, 致使钢锚抵御冲击载荷能力降低, 最终在应力集中部位断裂。     

高强度双头螺柱断裂失效分析

通过对双头螺柱化学成分、力学性能和金相组织进行分析,以及对其断口进行宏观形貌和微观形貌观察,最终确定双头螺柱断裂失效是由于表面螺纹沟槽处的大量氢鼓泡受到拉应力的作用在沟槽表面形成微裂纹造成的。     

A critical evaluation of indentation crack lengths in air

An extensive overview is presented of Vickers indentation crack lengths in ceramics in air. Measurement of such crack lengths is one of the most common and powerful assessments of the fracture properties of ceramics and the overview provides a critical evaluation of observed behavior as functions of material type and indentation load, and an extensive basis for comparison of results from new materials and analyses. The overview considers single crystals, polycrystals, transforming materials, glasses, and multiphase materials, including cermets, glass-ceramics, and tooth enamel. The coverage extends over structural and electronic ceramics, including oxides, carbides, nitrides, and titanates. The data are presented in a single format for ease of interpretation in terms of idealized indentation fracture and for inter-material comparisons; most data are unique to this work, but the results of selected studies from the published literature are included. The overview considers the precision and accuracy of crack length measurements and demonstrates a simple quantitative evaluation and ranking scheme for ceramic fracture based on load-adjusted crack length and cracking susceptibility. Indentation hardness and cracking threshold are also determined and related to the susceptibility. Material toughness is related to cracking susceptibility by fracture mechanics analyses: typical crack length measurements in air are shown to provide estimates of inert toughness with a relative uncertainty of ±50%.     

42CrMo锚栓断裂分析

风电用42CrMo锚栓在安装过程中突然发生断裂，对断裂试样进行化学成分分析，采用金相检验与扫描电镜观察相结合的方法，分析研究断裂原因。结果表明，断口为沿晶断裂，锰元素含量超标和磷、硅、铜合金元素晶界偏聚是造成沿晶断裂的主要原因；另外，热处理时淬火温度过高造成奥氏体晶粒粗大，以及回火温度接近高温回火脆性区造成杂质元素在奥氏体晶界偏聚，这些因素的共同作用也会导致材料发生脆性断裂。