Investigation of the Failure of an Automobile Torsion Bar

This paper presents the failure analysis of a steel torsion bar of the automobile suspension system. The bar fractures in service and the fracture surface was 45° to the axis of the bar, with radial marks and shear lips, characteristic of the brittle fracture of a mechanical element under torsion. Scanning electron microscope was used to characterize the fracture surface that did not present evidence of extensive plastic deformation. The torsion bar fracture initiated at a weld point which had produced a fatigue crack and a martensite transformation in the heat-affected zone. The instrumented indentation technique was used for the mechanical characterization (microhardness and elastic modulus) of the microscopic and macroscopic regions near failure. The heat-affected zone was approximately 400–600 μm in thickness and the weld was a “point” approximately 4 mm diameter. The results obtained allowed differentiating the tempered martensite from the martensite (without tempering) in the heat-affected zone, the latter being 47% harder.     

Finite element analysis of residual stress in the welded zone of a high strength steel

The distribution of the residual stress in the weld joint of HQ130 grade high strength steel was investigated by means of finite element method (FEM) using ANSYS software. Welding was carried out using gas shielded arc welding with a heat input of 16 kJ/cm. The FEM analysis on the weld joint reveals that there is a stress gradient around the fusion zone of weld joint. The instantaneous residual stress on the weld surface goes up to 800 ∼ 1000 MPa and it is 500 ∼ 600 MPa, below the weld. The stress gradient near the fusion zone is higher than any other location in the surrounding area. This is attributed as one of the significant reasons for the development of cold cracks at the fusion zone in the high strength steel. In order to avoid such welding cracks, the thermal stress in the weld joint has to be minimized by controlling the weld heat input.     

基于断裂力学的钢框架梁柱节点抗震性能分析

介绍了8 个足尺节点试验的结果与连接焊缝断裂破坏的现象。采用二维有限元断裂模型,研究了抗弯钢框架梁柱节点的断裂行为。以I 型裂纹尖端应力强度因子K_I和J积分为定量评价指标,分析了焊接孔形式、初始缺陷尺寸及位置、焊接垫板、角焊缝补强等设计细节对节点材料断裂韧性需求的影响。弹性分析表明,切除垫板并以角焊缝补强的措施,能最有效地降低对材料韧性的要求。弹塑性分析表明,焊接高匹配时热影响区裂纹比界面裂纹对材料韧性的要求更高,且局部塑性应变累积使材料的断裂韧性降低;解释了节点试验中断裂易发生在梁下翼缘焊缝热影响区的现象。基于断裂分析得到的节点抗弯承载力与试验中节点的极限弯矩吻合较好,该文的研究为钢框架梁柱节点的防断设计提供了参考。     

Deformation behavior and mechanical properties of braided rectangular pipes

The purpose of this study is to clarify the deformation behavior and the relationship between the braiding angle and mechanical properties for the braided rectangular pipe. Three-point bending test was performed for each specimen. Furthermore, the effect of the solid-core bar on the deformation state of the rectangular pipe was studied by finite element method (FEM). Moreover, the effect of the braiding angle on the deformation behavior in detail was investigated. The bending modulus and the bending strength for each specimen were decreased with an increase in the braiding angle. The local deformations occurred at the compression side under loading nose and decreased with an increase in stiffness properties in circumferential direction. From FEM analysis, using the aluminum solid-core bar was effective to restrain the local deformation. The difference between the bending moduli of experiments and FEM was decreased with an increase in the modulus in transverse direction.     

不锈钢管道焊缝区域的海水腐蚀性能

通过化学成分分析、金相试验和腐蚀试验,分析了不锈钢管道焊缝及附近区域耐海水腐蚀的特点,揭示了该焊缝及附近区域的海水腐蚀规律,并总结出该焊缝及附近区域金相组织变化对耐海水腐蚀性能的影响。     

Failure analysis of an A333Gr6 pipeline after exposure to a hydrogen sulfide environment

The analysis of an A333Gr6 pipeline failure was conducted after exposure to high H₂S partial pressure for several hours. Chemical composition, metallurgical structure, steel pipe hardness, and the welding joint near the broken position were studied. The chemical compositions of corrosion products inside the steel pipe were also analyzed. Results show that corrosion products consist of Fe₃O₄ and FeOOH without ferrous sulfide. Stress analysis was obtained through the finite element analysis method. The failure analysis and calculation results show that spontaneous ferrous sulfide combustion in a high H₂S environment leads to high temperature and pressure in the pipe, resulting in pipeline breakage.     

三辊斜轧空心减径的辊形设计及实验验证

以三辊斜轧空心减径过程中辊形对轧制过程的影响规律为研究对象,对无缝钢管三辊斜轧空心减径过程进行分析研究,建立了辊型的数学模型.利用有限元软件分析辊形曲线对成形过程的影响,并在某三辊实验轧机上进行实验分析,将实验结果与有限元模拟结果进行对比和分析.结果表明,当减径量小于10 mm时,入口锥角为2.5°的辊型对应的轧件在接近均整变形区金属流动十分平缓和均匀,轧件前端面也从三角形截面逐步变为圆截面;当减径量在14 mm左右,采用入口锥角为3.5°的辊型时轧件的质量较好.     

Modeling of failure mode of laser welds in lap-shear specimens of HSLA steel sheets

Failure mode of laser welds in lap-shear specimens of high strength low alloy (HSLA) steel sheets is investigated in this paper. The experiments for laser welds in lap-shear specimens under quasi-static loading conditions are briefly reviewed first. The experimental results showed that the laser welds failed in a ductile necking/shear failure mode and the ductile failure was initiated at a distance away from the crack tip near the boundary of the base metal and heat affected zone. In order to understand the failure mode of these welds, finite element analyses under plane strain conditions were conducted to identify the effects of the different plastic behaviors of the base metal, heat affected zone, and weld zone as well as the weld geometry on the ductile failure. The results of the reference finite element analysis based on the homogenous material model show that the failure mode is most likely to be a middle surface shear failure mode in the weld. The results of the finite element analysis based on the multi-zone non-homogeneous material models show that the higher effective stress–plastic strain curves of the weld and heat affected zones and the geometry of the weld protrusion result in the necking/shear failure mode in the load carrying sheet. The results of another finite element analysis based on the non-homogeneous material model and the Gurson yield function for porous materials indicate that the consideration of void nucleation and growth is necessary to identify the ductile failure initiation site that matches well with the experimental observations. Finally, the results of this investigation indicate that the failure mode of the welds should be examined carefully and the necking/shear failure mode needs to be considered for development of failure or separation criteria for welds under more complex loading conditions.     

Finite element modelling of closed cracks in eddy current testing

The eddy current inspection of small fatigue cracks in Ti–6AL–4V is evaluated in both a finite element model and experiments. The crack was created in a fatigue process and an eddy current measurement was carried out as the resulting crack was subjected to different levels of static load. The signal showed a strong dependency of the time between the creation of the fatigue crack and the eddy current measurement. This dependency is proposed to be related to oxides forming on the crack faces. The oxide is favourable for the detection of fatigue cracks. The narrow width of the fatigue crack is important to consider in eddy current inspection and as static loads are applied across the crack faces, electrical connections arise within the crack, which has a strong influence on the eddy current signal. Four different models of the contact behaviour were implemented within the finite element model. It is shown that the electrical connections that arise within small fatigue cracks, as well as the influence from the narrow opening as tensile loads are applied, can be predicted by a finite element model of the eddy current method.     

Mandrel Peeling of a Flexible Laminate With a Pressure‐Sensitive Adhesive: Comparison of Experiment with Numerical Analysis

Abstract: Mandrel peel tests with mandrels or rollers of varying diameters have been carried out using Mylar backing of several thicknesses and a commercial synthetic acrylic adhesive. The results are critically compared with the numerical predictions of the peeling software package ICPeel. In addition, a finite element model of the mandrel peeling process has been completed which gives good agreement with experiment provided appropriate mechanical properties of adherend and adhesive are used which must include the effects of adherent constraint. The influence of the thickness of the backing is also considered and both experiment and analysis confirm that there is a backing thickness at which the peel force for a laminate of this sort will show a maximum.     

基于CFD和试验的商用车高位引气管预滤性能的 分析与优化

为延长恶劣工况下某商用车进气系统空气滤清器滤芯的使用寿命,避免频繁更换滤芯,提出了增加旋流扇的高位引气管方案,并通过优化旋流扇夹角来提高进气系统预滤灰尘和液雾的效率,达到降低成本的目的。首先,采用计算流体力学（computational fluid dynamics,CFD）方法,对进气过程中高位引气管的内部流场进行数值模拟,分析了3款高位引气管的速度流线图和速度梯度云图,得到了高位引气管预滤灰尘和液雾的机理,并基于高位引气管速度流场的变化规律,提出了旋流扇夹角优化方向;其次,利用台架试验对优化后的高位引气管进行灰尘和液雾的预滤试验,并计算出灰尘和液雾的预滤效率;最后,对比不同高位引气管预滤灰尘和液雾的效率,根据两预滤效率的变化趋势,选择旋流扇最优夹角为75°。仿真和试验结果表明：旋流扇夹角对进气系统工作过程中高位引气管的流场及预滤效率有重要影响,优化旋流扇夹角有助于提高进气系统的预滤性能,从而减少进入空气滤清器的灰尘和液雾,达到延长空气滤清器滤芯寿命的目的。     

Analysis of shape and location effects of closely spaced metal loss defects in pressurised pipes

Metal loss due to corrosion is a serious threat to the integrity of pressurised oil and gas transmission pipes. Pipe metal loss defects are found in either single form or in groups (clusters). One of the critical situations arises when two or more defects are spaced close enough to act as a single lengthier defect with respect to the axial direction, causing pipe ruptures rather than leaks, and impacting on the pressure containing capacity of a pipe. There have been few studies conducted to determine the distance needed for defects to interact leading to a failure pressure lower than that when the defects are treated as single defects and not interacting. Despite such efforts, there is no universally agreed defect interaction rule and pipe operators around the world have various rules to pick and choose from. In this work, the effects of defect shape and location on closely spaced defects are analysed using finite element analysis. The numerical results showed that defect shapes and locations have a great influence on the peak stress and its location as well as the failure pressure of pipes containing interacting defects.     

Analysis of refrigerant flow and deformation for a flexible short-tube using a finite element model

A finite element model was used to simulate single-phase flow of R-22 through flexible short-tubes. The numerical model included the fluid-structure interaction between the refrigerant and the deformation of the short-tube as upstream pressure was varied. The finite element model was developed using a commercially available finite element package. Short-tubes with moduli of elasticity ranging from 5513 to 9889 kPa were studied. Four upstream and downstream pressures were applied and the upstream subcooling was held at a constant value of 16.7 °C. Mass flow rates from the numerical model were compared to available published experimental results. The study showed that upon deformation the short-tube resembled the shape of a converging-diverging nozzle. Both tube inlet and outlet had a chamfered-like shape after deformation which reduced the pressure drop at the tube inlet. The smaller the modulus of the tube, the larger the chamfered-like angle at the inlet and the higher the pressure drop along the tube due to the higher tube contraction. The results illustrated that as the upstream pressure was increased by 45%, there was almost a 60% decrease in the flow area. The more flexible (5513 kPa) short-tube restricted the mass flow rate more than the most rigid (9889 kPa) short-tube used in this study. The mass flow rates estimated with the finite element model were as much as 14% higher than those from experimental results reported in the literature.     

内置高温热管C/C复合材料热防护结构热力耦合机制

采用内置高温热管的热防护结构是一种新型高效的热防护方式。建立了内置高温热管的C/C 复合材料热防护结构模型, 并通过罚函数的方法引入C/C 复合材料与高温热管间装配关系, 推导了一种顺序耦合的热力耦合有限元格式, 在此基础上对热防护结构进行了热力耦合计算分析, 最后对影响结构温度场与应力场的若干参数进行了参数影响分析。计算结果表明, 在典型飞行状态下, 采用内置高温热管的C/C 复合材料热防护结构能确保结构驻点温度在材料许用温度范围内; 同时, 采用预留装配间隙的方法可有效降低结构界面的接触应力。该方法也可进一步用于研究由接触热阻引起的热力耦合问题。      

基于热流耦合精细算法的大体积混凝土水管冷却数值模拟

基于有限元热流耦合精细算法进行大体积混凝土施工期温度场仿真分析,真实反映水管附近的温度梯度和水管水温沿程的变化,采用基于粒子迁徙的粒群算法对Dittus-Boelter方程进行参数识别,使之适用于描述冷却水流的强制对流特性.在通用有限元软件ABAQUS 平台上,开发热流耦合用户子单元,以官地碾压混凝土重力坝某一浇筑块为例验证热流耦合算法和用户子单元的可靠性和合理性.计算结果表明:精细算法能真实反映混凝土浇筑块的温度场,同时基于精细算法得到的施工期应力略大于等效算法.     

Development of cementless metal-backed acetabular cup prosthesis using functionally graded material

Metal backing has become widely used in acetaular cup design. A stiff backing for a polyethylene liner was initially believed to be mechanically favorable. Yet, recent studies of the load transfer around acetabular cups have shown that a stiff backing in fact generates higher stress peaks around the acetabular rim than full polyethylene cups, while reduces the stresses transferred at the central part of acetabulum causing stress shielding at the dome of acetabulum. To overcome these two problems, the aim of this study is to improve the design of cementless metal-backed acetabular cup using the two-dimensional functionally graded material concept through a finite element analysis and the optimization techniques. It is found that the optimal 2-D FGM model has three bioactive materials of hydroxyapatite, Bioglass and collagen. This optimal material reduces the stress shielding at the dome of acetabulum by 40% and 37% compared with stainless steel and titanium metal backing shell, respectively. However, using 2-D FGM model reduces the maximum interface shear stress in bone by 31% compared to titanium metal backing shell.     

Mathematical simulation of the strength of a pipe with three-dimensional defect

We develop a mathematical model of plastic fracture of a thin-walled pipe with three-dimensional part-through “smooth” defect and compute the degree of weakening caused by this defect. The defect is simulated by an elliptic (in plan) slot appearing in the pipe. It is necessary to find the level of internal pressure under which the material in the zone of the defect passes into the limiting state. or sufficiently deep defects whose sizes are much smaller than the radius of the pipe, the problem of determination of the stress-strain state in the zone of the defect under given internal pressure is reduced to the solution of a nonlinear system of two one-dimensional integral equations. This system is solved by using an original algorithm and the limiting pressure is found within the framework of the proposed mathematical model. Under certain assumptions concerning the distribution of stresses in the zone of the defect, we deduce a formula which expresses the limiting pressure via the sizes of the defect and the strength characteristics of the material. The results of theoretical analysis are compared with numerical data obtained by the method of finite elements. PNVP “Integrator”. Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 34, No. 1, pp. 65–70, January–February, 1998.     

利用电磁超声横波检测二冷区尾端连铸坯壳厚度

使用电磁超声横波对二冷区尾端的连铸坯壳厚度进行检测,并建立了有限元仿真模型.选取Q235连铸小钢坯作为被测对象.为减小永磁铁的提离距离、在被测体内部生成更大的感应涡流,文章利用多物理场有限元仿真软件建立了一种不同于一般结构的电磁超声换能器仿真模型:圆柱形永磁体两侧并行排列螺旋线圈.分析了永磁铁尺寸对磁场涡流的影响以及电...     

Thermal elasto-plastic computation model for a buried oil pipeline in frozen ground

The 813-mm-diameter China-Russia Crude Oil Pipeline enters northeastern China at Lianyin, Mo'he County, Heilongjiang Province and crosses 441 km of warm discontinuous, sporadic and isolated patches of permafrost and 512 km of seasonally frozen ground before reaching Daqing, China. It is inevitable that the buried pipeline is subject to frost heave and/or thaw settlement when it passes through regions of permafrost and seasonally frozen ground with available moisture. Therefore, stress and deformation analyses of the pipe subject to frost action or thaw settlement are important for the safety, long-term stability and economic feasibility of the buried oil pipeline system. Based on the (empirical) frost heave and/or thaw settlement coefficients, a simple thermal elasto-plastic finite element computation model is put forward for analyzing the stress and strain state of the pipe. The influences of soil temperatures on the soil deformation were considered, but those of the soil deformation on the soil temperatures were ignored in the modelling. Finally, two examples of the application of the computation model are presented, in which the stress and deformation of a pipe exposed to frost heave or thaw settlement is calculated. The results of the frost action computation show that the effective stress on the pipe increases linearly with the frost heave deformation. The largest pipe deformations and stresses may occur when crossing frost mounds due to differential frost heaving. The stress and deformation smooth out from the frost mound. The results of thaw settlement computation show that the pipe stress changes greatly near the interface of thaw settlement zone and no thaw settlement zone, and the thaw settlement has small effect on the stability of oil-pipeline. The computation results show that the oil pipeline design in the permafrost regions should pay more attention on frost heave hazard than thaw settlement hazard.     

Behaviour of stresses in circumferential butt welds of steel pipe under superimposed axial tension loading

A computational procedure is presented for analyzing behaviour of stresses in circumferential butt welds of carbon steel pipe subject to superimposed mechanical loading. Three-dimensional uncoupled thermo-mechanical finite element (FE) analysis method is developed in order to predict the weld residual stress states in circumferentially butt-welded steel pipe. The FE method is verified through the experimental work. Then, three-dimensional elastic–plastic FE analysis is carried out to investigate the behaviour of stresses in steel pipe circumferential welds undergoing superimposed axial tension loading using the weld residual stresses and plastic strains obtained from the thermo-mechanical FE method. The simulated results show that spatial variations of the weld residual stresses are present along the circumference and a rapid change of the residual stresses exists at the weld start/stop position, therefore three-dimensional FE analysis is essential to accurately simulate the circumferential welding of steel pipe. Moreover, when axial tension loading is applied to the circumferentially welded steel pipe, bending moment is generated at the weld area caused by the circumferential shrinkage of the weld during welding, thus affecting the axial and hoop stress evolutions in the course of mechanical loading.