复合材料薄壁管冲击断裂分析与吸能特性优化

为实现不同冲击载荷下的吸能管结构逆向设计, 应用复合材料强度和刚度理论, 计算得到树脂基纤维增强复合材料正交各向异性的力学参数, 同时应用非线性显式有限元算法模拟了轴向冲击载荷作用下管件的动态断裂过程。根据正交设计原理, 得到了管件比吸能与其几何参数之间的非线性映射关系, 并构造出了相应的响应表面。按照汽车正面碰撞对冲击加速度的要求, 应用序列二次规划算法对吸能管进行了优化设计, 得到了具有较优吸能效率和较小冲击力峰值的吸能管结构参数。结果显示: 方管的变形模式、吸能量、冲击载荷-位移曲线变化趋势、冲击载荷峰值等与试验结果吻合很好; 当管件的壁厚、截面长度、管长分别选取2.1、44、200 mm时, 可得到设计域内的最大比吸能29.23 J/g。      

AZ31B镁合金挤压矩形管的轴向压溃试验与吸能特性分析

对AZ31B镁合金挤压矩形截面管进行准静态轴向压溃试验,研究其破坏模式和吸能特性,并探索管件长度、截面尺寸、倒角诱导因素等对吸能特性的影响。结果发现镁合金矩形管轴向压溃时存在两种破坏模式:整体破坏模式和渐进破坏模式,无倒角时管件发生整体破坏,而管端有倒角时主要从倒角端开始发生渐进破坏。渐进破坏模式有利于管件吸收能量。镁合金管件具有良好的吸能特性,其比吸能优于钢管、铝合金管和复合材料管。     

钢结构防动载断裂选材的定量判据

分析了目前钢结构防断选材中应用的脆性转变温度方法的局限性,扼要介绍了材料断裂韧度的温度效应和加载速率效应.在钢材断裂特性分析的基础上提出了平面应变型断裂临界温度的概念,构建了断裂特征分析图,从而为钢结构防动载断裂选材提出了一个新的定量的判据,并以船只设计选材为例,阐明了该判据的应用.     

Analysis of the fatigue failure of a mountain bike front shock

We present an analysis of a mountain bike front shock failure. The failure of the 1-year-old shock occurred catastrophically as the bike was ridden off of a 1-m drop. The failure was the result of fast fracture through both shock tubes at the location where the tubes were press fit into the shock upper crown. Examination of the fracture surfaces of the tubes revealed regions of fatigue crack growth that nearly penetrated the entire thickness of both tubes. An estimate of the forces during use, coupled with stress analysis, revealed three stresses near the fracture site—axial compression, bending, and hoop stresses. During operation, the axial compressive stress is negligible while the hoop and bending stresses are significant. Based on fracture mechanics, and an estimate of the bending stress from a 1-m drop, it is confirmed that the fatigue cracks present on the fracture surface were large enough to induce fast fracture. Prior to the existence of the fatigue cracks, the stresses were magnified locally near the fracture site by a significant stress concentration caused by the sharp transition from the shock tube to the crown. The fatigue cracks initiated at a circumferential location in the tube commensurate with high tensile bending stress and the stiffest region of the crown (highest stress concentration). Based on the evidence, the most probable cause of the bike shock fatigue failure was the shock design, which facilitated high local stresses during use.     

Elastic-plastic fracture mechanics assessment for steam generator tubes with through-wall cracks

The present work provides an elastic‐plastic fracture mechanics (EPFM) assessment scheme for a steam generator tube with a through‐wall crack under internal pressure. Noting that the geometry and material are rather uniform for steam generator tubes, and furthermore the only loading to be considered is internal pressure, an engineering EPFM analysis method is proposed to assess through‐wall cracks in steam generator tubes. Important outcomes of the present work are closed‐form approximations for J and crack opening displacement (COD). Sufficient confidence in the proposed J and COD estimates is gained from good agreements with the finite element results over a wide range of the crack length and pressure magnitude. Another important element of the EPFM assessment is to determine relevant J‐resistance curve for steam generator tubes. To improve the accuracy of predicting tube failure, the present paper also proposes a new method to determine fracture toughness using an actual tubular specimen instead of using a standard specimen, from which J‐resistance curves of steam generator tubes are obtained. Using the proposed J and toughness estimates, maximum pressures of steam generator tubes with through‐wall crack are estimated based on EPFM analysis, which is compared with experimental results and predicted ones based on limit load approach.     

Role of geometry in plastic instability and fracture of tubes and sheet

Conditions for plastic instability and fracture for biaxially loaded tubes are compared to those for a sheet to assess the role of geometry. Thin-walled tubes of 70-30 brass were loaded in combined axial tension-internal pressure. The strains for diffuse instability, local instability and fracture were measured and compared to results on brass sheet. Uniform deformation (up to diffuse instability) was found to be very sensitive to geometry in agreement with theory. The uniform strain in tubes for axial plane strain is twice that for hoop plane strain and the uniform strain in tubes for balanced biaxial tension is only one third of that for sheet. The strain levels for local instability and fracture did not depend on geometry. No significant differences were found for axial vs. hoop loading in tubes and the critical strain levels for tubes were actually somewhat greater than those for sheet. Although the critical local strains are similar, the amount of useful (genera) deformation beyond diffuse instability for tubes is very limited because localization occurs rapidly. In bulged or punched sheet the geometry is stable and localization occurs gradually, providing significant post-uniform deformation.     

A survey of fracture mechanics applications in the united states

Results are presented in graphical form based upon data collected in a survey of fracture mechanics applications in the United States, which was conducted during the first half of 1975. The participants numbered 235 designers, engineers and scientists from industry, government and university. The survey considered the field of fracture mechanics in its broadest sense, including all areas of design which involve the various aspects of fracture in solids. The questionnaire used in the survey is given in an Appendix. Continuing input is sought to the established data base on fracture in design, and completed questionnaires should be sent to T. P. Rich.     

Analysis of the fracture of solids and flows of liquids in the theory of phase transitions

We suggest a new approach to the analysis of the processes of deformation and fracture in solids and flows of liquid in smooth tubes. It is based on the theory of phase transitions. For the processes of deformation and fracture under the conditions of fatigue, creep, and impact loading and for flows of liquids in smooth tubes, we determine the fundamental characteristics of phase transitions (order parameters and critical exponents). The power-law dependences established for fracture processes may be useful for the evaluation of the residual service life of materials and structures in the stage which precedes the appearance of critical damage or macrocracks of critical length. The outlined approach and the estimates of critical exponents obtained as a result of its application enable one to compare the regularities of phase transitions in different media. Baikov Institute of Metallurgy, Russian Academy of Sciences, Moscow. Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 32, No. 3, pp. 63–72, May–June, 1996.     

Developing a hybrid procedure of one dimensional finite element method and CFD simulation for modeling refrigerant flow mal-distribution in parallel flow condenser

Mal-distribution of refrigerant flow in flat tubes is an important problem in parallel flow heat exchangers (PFHXs) which should be considered in heat exchanger modeling. In the present study, a hybrid method is developed for flow distribution forecasting based on simultaneous use of computational fluid dynamics (CFD) simulation for 3D analysis of flow in PFHX headers and one dimensional finite element model for solving flow within flat tubes. The experimental data of a parallel flow condenser (PFC) performance is collected to verify the developed method. The average absolute deviations of 2.8%, 4.1% and 3% from experimental data for pressure drop, capacity and outlet temperature respectively, indicate the model validity. Slight increase of mass flow rate with moving toward the bottom tubes of the inlet header shows insignificant effect of gravity when vapor-phase flow is present. Also, comparing the pressure drop data of the developed method with those of uniform-distribution model demonstrates reduction of average absolute deviation from 28.7% to 2.8%. The proposed model has the advantage of predicting PFC overall performance and can be used to accurately design and optimize headers and multiport flat tubes.     

Fracture of prismatic aluminum tubes under reverse straining

The effect of loading history on fracture was thoroughly investigated at the material and structural level. Tests on tensile fracture of initially pre-compressed round specimens were analyzed and two alternative methods were developed to account for the effect of strain reversal on initiation of fracture in uncracked bodies. A complete calibration for plasticity and fracture without and with history effect was performed for 2024-T351 aluminum alloy. In the present approach, it is postulated that fracture occurs when the accumulated plastic strain modified by the effect of stress triaxiality and the loading history reaches a critical value. The newly developed theory then was applied to predict initiation of fracture in prismatic square aluminum tubes subjected to crush loading. Compression tests were performed on small columns with the width to thickness ratio covering the range 10–30. First fracture was observed at different locations depending on the thickness of the tube. The numerically predicted point of fracture initiation and the displacement corresponding to formation of crack agreed well with test results. It is concluded that the effect of loading history must be included in the formulation of fracture criteria and in the application to the failure analysis of structural components where large pre-compression should be expected.     

A method to predict failure pressures of steam generator tubes with multiple through-wall cracks

This paper proposes a simple numerical method to predict burst pressures of steam generator tubes with multiple through-wall cracks, based on the stress-modified fracture strain damage model with stress reduction technique. For validation, simulated results using the proposed method are compared with 31 published experimental data of Alloy 600 plates and tubes with single or two through-wall cracks, showing that predicted loads are within 10% of experimentally-measured ones for all cases considered. Furthermore, a parametric study is performed to investigate the interaction effect of two through-wall cracks in Alloy 600 steam generator tubes under internal pressure.     

基于知识工程驱动的导管智能工艺设计系统的开发与应用

目的 实现工业金属导管数字化快速制造,提高导管制造质量,缩短装备研制周期。方法 采用基于知识工程驱动的三维数字化设计技术、人工智能技术、计算机仿真技术,开发导管数字化制造集成系统,该系统主要包括导管数字化制造子系统、拼装夹具数字化设计子系统和系统管理子系统,进行导管三维建模、工艺设计与仿真、拼装夹具设计和导管数字化检测,实现金属导管数字化快速制造。结果 实现了多种装备上千种不同类型导管的数字化快速制造,提高了生产效率,导管数模的利用率达100%,导管试装合格率达78%,制造周期缩短了2个月,生产成本显著降低。     

On quasi-static crushing of thin-walled steel structures in cold temperature: Experimental and numerical studies

The aim of the study reported herein was to investigate the effects of low temperatures on the crushing characteristics of steel plated structures. The motivation of this study is for the analysis of ship collisions in Arctic waters. A series of tensile coupon tests were performed to examine their material behaviour at low temperatures, and then quasi-static axial crushing tests were carried out on thin-walled square tubes. The test tubes were made of ASTM A500-type carbon steel, and both the tensile coupon tests of the material and the crushing tests of the tubes were performed in a liquid nitrogen cooled chamber. To reflect the conditions of the Arctic environment more realistically, the tensile coupon tests of the material were also carried out in a dry-ice cooled chamber. LS-DYNA nonlinear finite element method simulations applying a practical approach of modelling techniques were performed to investigate the structural crashworthiness of the thin-walled steel tubes numerically. The tests in the liquid nitrogen cooled chamber showed that the fracture strain of the material was not affected (reduced) by temperatures as low as −80 °C, although fracture strain was significantly reduced below −100 °C. The fracture strain results obtained in the dry-ice cooled chamber, however, show this strain to be affected (reduced) by low temperatures even between 0 °C and −80 °C, which is equivalent to the Arctic environment. It was also observed that fracture occurs in thin-walled tubes under crushing loads at low temperatures. The LS-DYNA computations also detected the fracture behaviour of test tubes in cold temperatures in a relevant way.     

Damage tolerance based shape design of a stringer cutout using evolutionary structural optimisation

This paper uses a modified evolutionary structural optimisation (ESO) algorithm for optimal design of a stringer cutout used in many pressured fuselages of transport aircrafts. Both stress and fracture based ESO algorithms are studied. Initially, a stress optimised shape of the stringer cutout is determined. It is found that the ESO method significantly reduces the peak stress on the boundary. A residual strength based optimisation is then performed. The fracture based evolutionary structural optimisation algorithm uses residual strength as the design objective. The formulation used here allows for numerous cracks to be located along the entire structural boundary. The fracture ESO algorithm considerably improves the residual strength by decreasing the maximum stress intensity factor. It also reduces the variability in the stress intensity factors for the optimum shape and produces a near uniform level of fracture criticality around the boundary. It is also shown that the shapes optimised for stress and fracture strength may differ, and a fracture strength based optimisation may produce a lighter design. This highlights the need to explicitly include fracture parameters in the design objective function.     

某锅炉换热器换热管断裂原因分析

某锅炉换热器仅运行2 h即发生换热管断裂事故,采用光学显微镜、扫描电子显微镜、能谱仪、拉伸试验机和直读光谱仪等设备对换热管的断裂原因进行了分析。结果表明:该换热管外壁表面在运行前就已存在原始横向裂纹和机械损伤,在服役过程中这些裂纹和机械损伤处容易形成应力集中,加之换热管的使用温度较低,从而导致其在运行仅2 h后就发生早期脆性断裂。最后对该换热管的生产提出了建议。     

Fatigue behaviour characterization of the fibre-matrix interface

The fracture behaviour of FRP composite materials is significantly influenced by the behaviour of the fibre-matrix interfacial bond. Thus far interfacial bond mechanical characterization has been based upon the critical strength and critical fracture energy of debonding. Characterization of the fatigue behaviour of the interfacial debonding process, however, may be more valuable for composite design and fibre-matrix selection. A fracture mechanics model of interfacial bond fatigue based on the mode II strain energy release rate (G _II) is presented. An expression forG _II is derived for a single fibre in matrix cylinder model. By fitting the model to single fibre pull-out fatigue test data, fatigue crack propagation plots for specific fibre-matrix combinations can be drawn. These should prove useful for the development of fatigue resistant FRP composite materials.     

Application of non-destructive and fracture mechanics techniques for the condition assessment of naphtha hydrotreater furnace tubes in oil refinery

Furnace tubes of oil refineries undergo thermal, mechanical and environmental loadings during the lifetime of the plant. Apart from highly corrosive conditions, components are also under severe temperatures and pressures which lead to the material degradation and ultimately causing failure. Due to these loadings, the tubes have a finite life and it is important to monitor the condition of the tubes during inspection to avoid any rupture during the service.The aim of the present work is to evaluate the condition of the naphtha hydrotreater furnace tubes of an oil refinery. These tubes were manufactured of SA 312 P321 material and remained in service for about twenty-five years. Two different techniques were applied for the condition assessment of used and fresh tubes – non-destructive (ND) examination and fracture mechanics based fractographic evaluation. Based on the ND testing, significant deterioration of material was noted in the used specimens. Similarly, besides micro-structural defects, the used material also exhibited sufficient loss of hardness. On the other hand, mechanical properties obtained from standard tension, impact and bend tests also exhibited the poor condition of the tubes. A comparison of the used specimens with the un-used one shows that the condition of the furnace tubes has been considerably deteriorated and its further use for the long term service cannot be considered as satisfactory.     

Investigation of failure behavior of two different types of Zircaloy clad tubes used as nuclear reactor fuel pins

Nuclear reactor fuel pins act as barriers to the release of radioactive fission products to the coolant flowing around these thin-walled tubes and hence they prevent the leakage of radioactivity to the surroundings of reactor core. These tubes are of small thickness in order to have less resistance in the path of heat flow from the fuel to the coolant. Investigation of failure behavior of these fuel clad tubes is of utmost importance to the designers and plant operators in order to ensure the maximum residence time of the fuel bundles inside the reactor core as well as to ensure minimal activity during operation and refueling activities. Various types of zirconium based alloys are used to manufacture these pins. The focus is to obtain better strength, ductility, corrosion resistance, oxidation resistance, and minimal creep including those due to irradiation-assisted damage and deformation processes. Two number of such types of alloys, namely, re-crystallization annealed Zircaloy-2 and stress-relief annealed Zircaloy-4, have been investigated in this work for their fracture behavior. As standard fracture mechanics specimens cannot be machined from these thin-walled tubes, non-standard specimens with axial cracks have been used in this work. Load normalization technique has been used to evaluate crack growth during loading of these specimens. It was observed that the re-crystallization annealed Zircaloy-2 specimens have higher initiation fracture toughness as well as higher resistance to crack growth compared to the other type of specimens. In order to understand the micro-structural aspects of the fracture resistance behavior of these materials, further investigation incorporating optical and transmission electron microscopy have also been carried out. It was concluded that the higher fracture resistance behavior of the re-crystallization annealed Zircaloy-2 specimens can be attributed to the presence of finer grain and sub-grain micro-structure, very low dislocation density and other defects in the material.     

Partial Load: A Key Factor Resulting in the Failure of Gear in the Wind Turbine Gearbox

Gearbox is a critical component in the wind turbine system which can transfer wind energy into wind power to replace some fossil energy in order to reduce the environmental pollution. A 1.5-MW wind turbine gearbox failed after about 5 years of service; however, the design life of the gearbox is 20 years. In this paper, the failure mechanism of the gearbox was investigated based on standard failure analysis procedures and finite element (FE) simulation. The failure of gear could be attributed to fatigue fracture, because typical macroscopic features—beach marks and ratcheting marks—could be observed on the fracture surface. Furthermore, contact fatigue caused the formation of pits on the failed working tooth flank, even brought some microcracks. It should be emphasized that fatigue pitting mainly concentrated at the left end of the failed gear. Based on the physical, chemical analysis, and FE simulation, the failure of gear should be essentially ascribed to abnormal load rather than the material defects. Finally, based on the failure characteristics, partial load should be responsible for the failure of the gear in the wind turbine gearbox.     

Finite element analyses on transverse impact behaviors of 3-D circular braided composite tubes with different braiding angles

This paper presents finite element analyses (FEA) on the transverse impact responses of 3-D circular braided composite tubes with the braiding angles of 15°, 30° and 45°. A finite element model of the braided composite tube was established at microstructure level to analyze the transverse impact behaviors. From the FEA results, the impact damage, deformation and stress distribution were obtained to analyze the damage mechanism. Stress propagation in lower braiding angle tubes was faster than that of the higher braiding angle. The impact responses of the braided composite tubes were also tested to obtain load–displacement curves and energy absorption for the comparisons with the FEA results. The impact damage and fracture morphology obtained from the FEA were in good agreement with the experimental results, which demonstrated the feasibility of the FEA model for the design of the braided tube.