A simple method to calculate mode components of strain energy release rate of free-edge delaminations in composite laminates

A simple method, which calculates the mode components of the strain energy release rate of free-edge delaminations in the laminates, is proposed. The interlaminar stresses are evaluated as an interface moment and interface shear forces that are obtained from the equilibrium equations at the interface between the adjacent layers. Deformation of an edge-delaminated laminate is calculated by using a generalized quasi-three dimensional classical lamination theory developed by the author. The analysis provides closed-form expressions for the three components of the strain energy release rale. The analyses are performed on [+30/−30/90]s laminates subjected to uniaxial extension, with free-edge delaminations located symmetrically and asymmetrically with respect to the laminate midplane. Comparison of the results with a finite element solution using the virtual crack closure technique shows good agreement. The simple nature of this method makes it suitable for primary design analysis for the delaminations of composite laminates.     

基于最小能量法的高速切削锯齿状切屑变形分析

以高速切削典型变形特征为研究对象,建立了锯齿状切屑的几何模型。根据高速切削绝热剪切理论,通过对剪切面相对滑移失稳瞬间的切屑块受力平衡分析建立力学模型和运动学模型,获得切屑摩擦力和剪切力及剪切速度和切屑流动速度,并确定了切削能量方程。在考虑应变、应变率、切削温度和变形硬化因素条件下按最小能量原理求变形方程,结合变形曲线的分析和切削理论确定了高速切削变形方程及影响变形的因素。分析结果表明,切屑锯齿化是塑性变形超过临界失稳条件的结果。     

Energy release rate of postbuckled laminates with a through-width delamination

The strain energy release rate is calculated for buckled one-dimensional delamination (through-width delamination) in composite laminates subjected to in-plane compression. A crack closure method based on plate finite elements is used in this analysis. For some laminates containing a one-dimensional delamination in cylindrical bending, closed form solutions are available. The present finite element solutions show excellent agreement with the analytical solutions. The strain energy release rate for various types of laminates is also calculated using the present finite element method. The results show that the strain energy release rate strongly depends on the type of laminate.     

UNDERSTANDING OF FINITE ELEMENT ANALYSIS RESULTS UNDER THE FRAMEWORK OF OXLEY'S MACHINING MODEL

We introduce an accurate coupled thermo-mechanical finite element analysis (FEA) of machining using the Arbitrary Lagrangian Eulerian (ALE) analysis capability of ABAQUS/Explicit. This analysis provides detailed information about the cutting forces, chip thickness, contact length, the extent of the primary and secondary shear zones as well as the distribution of strain, strain rate and temperature in the deformation zones. This information has to be viewed under the framework of an analytical model for it to lead to better understanding of the physics of machining. We use the best available analytical model, namely, Oxley's machining model, for this purpose and the FEA results are compared with the assumptions and predictions of Oxley's analysis. The strain rate in the primary shear zone, the hydrostatic pressure variation along the shear plane, the distribution of normal and shear stresses along the tool-chip interface and the shape of the secondary shear zone are the quantities compared. Due to the key role of temperature in the prediction of tool wear, the fraction of heat conducted away into the workpiece, the maximum temperature along the tool-chip interface and the maximum temperature along the flank face are also compared. The comparison reveals that Oxley's model captures the physics of machining quite well. However, some details such as the heat partition module and the assumptions on stress and temperature distribution at the tool-chip interface need to be revisited.     

UNDERSTANDING OF FINITE ELEMENT ANALYSIS RESULTS UNDER THE FRAMEWORK OF OXLEY'S MACHINING MODEL

ABSTRACT

We introduce an accurate coupled thermo-mechanical finite element analysis (FEA) of machining using the Arbitrary Lagrangian Eulerian (ALE) analysis capability of ABAQUS/Explicit. This analysis provides detailed information about the cutting forces, chip thickness, contact length, the extent of the primary and secondary shear zones as well as the distribution of strain, strain rate and temperature in the deformation zones. This information has to be viewed under the framework of an analytical model for it to lead to better understanding of the physics of machining. We use the best available analytical model, namely, Oxley's machining model, for this purpose and the FEA results are compared with the assumptions and predictions of Oxley's analysis. The strain rate in the primary shear zone, the hydrostatic pressure variation along the shear plane, the distribution of normal and shear stresses along the tool-chip interface and the shape of the secondary shear zone are the quantities compared. Due to the key role of temperature in the prediction of tool wear, the fraction of heat conducted away into the workpiece, the maximum temperature along the tool-chip interface and the maximum temperature along the flank face are also compared. The comparison reveals that Oxley's model captures the physics of machining quite well. However, some details such as the heat partition module and the assumptions on stress and temperature distribution at the tool-chip interface need to be revisited.     

橡胶纯剪试件断裂力学分析

在橡胶材料纯剪试件中,当裂纹的长度和试件的高度尺寸接近时,应变能释放率与裂纹尺寸无关,由于存在这个特点,纯剪试件经常被用来研究橡胶材料的断裂属性。文中对橡胶纯剪试件在试件中心线上分别存在中心裂纹和边缘裂纹,以及粘接界面分别存在中心裂纹和边缘裂纹的情况进行非线性有限元分析,并将有限元计算的应变能释放率与已存在的解进行比较。对于长裂纹,有限元解与已存在的解吻合较好;但是对于小裂纹,有限元解与已存在的解之间仍然存在一些差异。     

A Study on the mechanics of shear spinning of cones

The shear spinning process, where the plastic deformation zone is localized in a very small portion of the workpiece, shows a promise for increasingly broader application to the production of axially symmetric parts. In this paper, the three components of working force are calculated by the newly proposed deformation model in which the spinning process is understood as shearing deformation after uniaxial yielding by bending, and shear stress, τ _rz becomesk, yield limit in pure shear, in the deformation zone. The tangential forces are first calculated and the feed forces and the normal forces are obtained by the assumption of uniform distribution of roller pressure on the contact surface. The optimum contact area is obtained by minimizing the bending energy required to get the assumed deformation of the blank. The calculated forces are compared with experimental results. A comparison shows that theoretical prediction is reasonably in good agreement with experimental results.     

Stress singularities at angular corners in first-order shear deformation plate theory

The first-known Williams-type singularities caused by homogeneous boundary conditions in the first-order shear deformation plate theory (FSDPT) are thoroughly examined. An eigenfunction expansion method is used to solve the three equilibrium equations in terms of displacement components. Asymptotic solutions for both moment singularity and shear-force singularity are developed. The characteristic equations for moment singularity and shear-force singularity and the corresponding corner functions due to ten different combinations of boundary conditions are explicated in this study. The validity of the present solution is confirmed by comparing with the singularities in the exact solution for free vibrations of Mindlin sector plates with simply supported radial edges, and with the singularities in the three-dimensional elasticity solution for a completely free wedge. The singularity orders of moments and shear forces caused by various boundary conditions are also thoroughly discussed. The singularity orders of moments and shear forces are compared according to FSDPT and classic plate theory.     

基于HyperWorks 的不同铺层方式复合材料剪切强度有限元分析

剪切强度和剪切韧性是反映复合材料构件在复合受力状态下承载能力及耗能能力的重要指标,不同铺层方式的单向玻璃纤维与短切玻璃纤维混杂增强复合材料层合板的层间剪切性能有明显差异。文中基于HyperWorks 商用有限元软件建立了精确的复合材料层合板模型,通过数值模拟分析不同铺层方式复合材料层合板的层间剪切性能。研究结果表明,铺层材料对复合材料层合板的层间剪切性能影响较大,而铺层顺序对复合材料层合板的层间剪切性能影响较小。     

The role of viscous deformation in the machining of polymers

This study aims to evaluate the machinability of typical thermoplastic and thermosetting polymers and understand the effect of their viscous properties on surface integrity, chip formation and machining forces. The interaction between the strain rate and temperature during machining was particularly addressed. It was found that the viscous deformation of a polymer plays a decisive role in determining the quality of a machined surface. To minimize the surface roughness, for instance, the machining conditions must be selected in such a way that the material removal deformation falls in the regime without visco-plastic scaling/tearing and brittle cracking. The optimal machining condition must be based on the polymer properties, such as the glass transition temperature, fracture toughness and molecular mobility. The shear stress in the shear plane of chipping is a good measure of the coupled effect of strain rate and temperature rise. In addition, the study discovered two new types of chips whose deformation and curling were in close relation to the surface integrity of the machined components.     

橡胶纯剪试件变形与断裂的有限元分析

用非线性有限元法分析橡胶纯剪试件变形与理想纯剪变形之间的差异.结果表明试件中心接近纯剪,但是靠近自由边界的区域应力比较复杂,受自由边界影响的区域随应变的增加而减小,试件的宽高比越大变形越接近理想纯剪变形.对橡胶纯剪试件存在中心裂纹和边缘裂纹时的撕裂能进行计算,断裂形成大裂纹时撕裂能与裂纹尺寸无关,有限元解与以前的结果吻合较好;对于小裂纹,撕裂能与裂纹尺寸成线性关系.同时分析不同材料模型对橡胶纯剪试件变形和断裂的影响.分析表明,不同应变能函数的材料模型模拟的结果略有不同.     

Design,development, and calibration of a force-moment measurement system for wheel–rail contact mechanics in roller rigs

A force measurement system, referred to as “dynamometer”, for accurately acquiring the contact forces and moment in a single-wheel roller rig using piezo-electric load cells is designed and developed. Accurate determination of the wheel–rail contact forces and moments is an essential requirement for studying the wheel–rail contact mechanics. The dynamometer is placed in the load-path between the wheel–rail interface and the ground, enabling it to measure the forces and moments at the interface. A series of tests are performed to determine the quasi-static and dynamic characteristics of the dynamometer. Additionally, finite element analysis and multi-body dynamic modeling are used to establish flexural modes and dynamic interface between the components. The simulation and test results indicate that the dynamometer is able to accurately and reliably measure the contact forces and moments at the wheel–rail interface.     

FRP 层压复合梁结构屈曲变形在线监测方法

为了实现梁结构屈曲变形在线监控,提出了一种FRP层合梁屈曲变形重构方法。首先,依据高阶剪切变形理论,提出了一种复合梁结构变形场描述方法,并基于冯卡门应变梯度理论,推导出了中性轴应变表述方式。然后,利用最小二乘变分法建立了位移重构模型。其中,利用四次B-样条基函数构造了屈曲变形位移插值函数,推导了理论中性轴应变计算公式。并基于少量应变测量,提出了非线性项应变解耦方法,建立了测量应变与实测中性轴应变转换关系。最后,为了验证所提方法的精确性,以25层碳纤维复合梁为样件,搭建固定-简支梁试验平台,对其进行数值计算和试验论证。结果表明,建立的屈曲变形重构模型在不同轴向载荷作用时,位移场重构误差均小于8%。     

An approximate solution to a problem of pseudo-steady flow of strain-hardening material

An approximate technique is presented for estimating an external force in steady or pseudo-steady flow of strain-hardening material, for which the deformation can be simplified to a rigid-body motion mechanism. The rigid blocks are separated from each other by layers of the material undergoing intensive shear. The strain-hardening effect is incorporated into the analysis by assuming the flow shear stress as an exponential function of equivalent strain. This technique, similar in its nature to the upper bound approach of limit analysis, cannot be rigorously regarded as such since the distribution of the shear stress and the boundaries in pseudo-steady state problems cannot be specified a priori. It is shown that the rate of work-dissipation within a shear layer depends on the total increase of the tangential velocity and is independent of its thickness, as in the case of perfectly plastic solids. The results of computations for a pseudo-steady pyramidal indentation of a strain-hardening solid are presented and compared to the experimentally measured forces reported by other authors. Computations for a pseudo-steady flattening of a tetrahedral asperity are also briefly reported.     

基于有限元法分析超精密切削中的摩擦问题

基于更新的拉格朗日公式,建立了热-机械耦合的平面应变大变形正交切削模型.根据此模型,对金刚石车削过程中的摩擦问题进行了仿真研究.对两种摩擦模型仿真所得的切削力与实验数据进行了比较,验证了前刀面上的摩擦状态应是粘结-滑移摩擦同时存在,并研究了刀具摩擦系数各向异性对超精密切削中切屑变形、切削力、剪切角的影响.     

器件韧性镀膜微划痕破坏机理研究

对硅基体上之韧性镀膜（铝膜）的粘结强度及破坏机理进行微划痕实验及理论研究,从实验中观察出该体系的破坏特征,进而测量出微划前水平驱动力、划痕深度随划前水平位移并伴随着界面脱胶发生的变化规律,针对微刈痕破坏特征,建立了双粘聚力模型,并对由微划痕引起的界面弹塑性脱胶进行了数值模拟,给出界面脱胶时能量释放率随其他材料参数变化的理论预测曲线,并将预测值与文中的铝／硅实验结果及与文献中关于铂／氧化镍的实验结果进行对比,达到基本符合。通过以对韧性薄膜／脆性基体的微划痕实验研究和理论分析,获得如下主要结论：（1）韧性膜的微划痕破坏特征为,当划刀尖端接近界面时,将突然发生薄膜测界面的脱胶现象,并在界面附近脆性基一侧形成界面裂纹并扩展;微划痕的水平驱动力表征了整个薄膜脱胶体系的能量释放率;薄膜或涂层材料的塑性变形对微划痕过程有较强的抑制作用。（2）界面的分离强度和材料的剪切强度对微划痕过程有重要的影响。（3）划痕刀片的几何特征角对刻痕水平驱动力影响不大。     

Effect of Cycling Low Velocity Impact on Mechanical and Wear Properties of CFRP Laminate Composites

The mechanical and wear properties of CFRP laminate were investigated using a method of cycling low velocity impact, to study the trend and mechanism of impact resistance of the CFRP laminate under repeated impact during its service process. The interface responses of CFRP laminate under di erent impact kinetic energy during the cycling impact process were studied were studied experimentally, such as impact contact duration, deformation and energy absorption. The worn surface morphologies were observed through optical microscopy and a 3?D surface profiler and the cross?sectional morphologies were observed through SEM to investigate the mechanism of impact material dam?age. Based on a single?degree?of?freedom damping vibration model, the normal contact sti ness and contact damp?ing of the material in di erent wear stages were calculated. It shows the failure process of CFRP laminate damaged by accumulated absorption energy under the cycling impact of di erent initial kinetic energy. The results indicate that the sti ness and damping coe cients will change at di erent impact velocities or cycle numbers. The damage mechanism of CFRP laminates under cycling low kinetic energy is delamination. After repeated experiments, it was found that there was a threshold value for the accumulated absorption energy before the failure of the CFRP laminate.     

Mechanistic and Finite Element Model for Prediction of Cutting Forces During Micro-Turning of Titanium Alloy

Titanium alloy Ti-6Al-4V is commonly used in biomedical applications due to its superior properties such as biocompatibility, high strength-to-weight ratio and corrosion resistance. To understand the mechanics of the micro-turning process of these alloys, a mechanistic model has been developed for predicting the cutting forces. A modified Johnson–Cook material model with strain gradient plasticity is used to represent the flow stress of work material. The micro-turning experiments were conducted to verify the cutting forces predicted by mechanistic model. A finite element model is also developed with different shear friction factors and calibrated using experimental results to confirm and interpret the results of mechanistic model. It is inferred that strain rate increases by increasing cutting speed, whereas it decreases with increase in the feed rate due to increase in adiabatic shear band spacing. Since Ti-6Al-4V has low thermal conductivity, when cutting speed increases, there is an increase in the tool-chip interface temperature that leads to decrease in cutting forces. When cutting speed increases, chip morphology changes from discontinuous to continuous, and there is significant deterioration in the surface finish. It is observed that the average cutting force prediction errors for mechanistic and finite element models are 9.69% and 11.45% respectively.     

Stability and free vibration analysis of thick piezoelectric composite plates using spline finite strip method

In the present study, a spline finite strip with higher-order shear deformation is formulated for stability and free vibration analysis of piezoelectric composite plates. At each knot, the electric potentials on the surfaces and middle plane of each piezoelectric layer are taken as nodal degrees of freedom. However, if a continuous electrode is installed on the surface of the layer, the electric potential on the electrode is changed to structural degree of freedom, so that the equipotential condition on the electrode is automatically satisfied. The analysis can be conducted based on Reddy's third-order shear deformation theory, Touratier's “Sine” model, Afaq's exponential model or Cho's higher-order zigzag laminate theory. Consequently, the shear correction coefficients are not required in the analysis, and an improved accuracy for thick plates over the first-order shear deformation theory is achieved at only little extra computational cost.The numerical results obtained based on different shear deformation theories are presented in comparison with the three-dimensional solutions. The effects of length-to-thickness ratio, fiber orientation, boundary conditions and electrical conditions on the natural frequency and critical buckling load of piezoelectric composite plates are investigated through numerical examples.