Development and validation of a probabilistic model for notch fatigue strength prediction of tool steels based on surface defects

A new model for the high cycle notch fatigue strength prediction of tool steels subjected to axial loading is proposed, based on previous literatures studies and experimental tests carried out on six different tool steels, including rotating bending fatigue tests on notched specimens, fractographic analyses, hardness, residual stress, and roughness measurements. The novelty is the assumption that surface defects are the main cause of notch fatigue failures of such steels. A probabilistic approach was implemented by modeling size distributions of defects, resulting in the prediction of normal distributions of fatigue strength. Like to other previous models, the effect of steel hardness, surface residual stress, notch severity, and specimen size was also taken into account. Model calibration and validation were performed using the data collected by the experimental activity. Model behavior was investigated by performing a sensitivity analysis, aiming to verify the response to variations of the considered input variables. Prediction errors of only 1.3% (on average) and 3.1% (maximum) resulted from the comparison between model-predicted and experimental notch fatigue strength.     

Proactive remanufacturing timing determination method based on residual strength

Nowadays, since the resources of remanufacturing are the ‘cores’, the uncertainty in quantity and quality of the ‘cores’ is an obstacle in remanufacturing engineering. To solve this problem, production management and design for remanufacturing have been discussed in the former studies. However, the current remanufacturing mode, which is carried out in the end of life cycle, is reactive. To delimit the uncertainty of ‘cores’, the concept of proactive remanufacturing is presented in this paper. And one issue is to identify the proactive remanufacturing timing. In the beginning, the reactive remanufacturing timing and proactive remanufacturing timing are introduced. Then, to characterise the remanufacturability of components, the concept of residual strength is proposed. To identify the proactive remanufacturing timing, the mathematical model is established based on the residual strength, remanufacturing value and technical feasibility. Based on this model, the timing determination method in proactive remanufacturing is presented and expanded. Finally, to validate this method, the proactive remanufacturing timing of engines is determined by analysing the crankshaft. As a consequence, in the proactive remanufacturing mode, the remanufacturing rate of product might be increased. Thus, the proactive remanufacturing could provide a new perspective in future remanufacturing engineering.     

Fracture mechanics analysis of a crack in a residual stress field

The standard definition of the J integral leads to a path dependent value in the presence of a residual stress field, and this gives rise to numerical difficulties in numerical modelling of fracture problems when residual stresses are significant. In this work, a path independent J definition for a crack in a residual stress field is obtained. A number of crack geometries containing residual stresses have been analysed using the finite element method and the results demonstrate that the modified J shows good path-independence which is maintained under a combination of residual stress and mechanical loading. It is also shown that the modified J is equivalent to the stress intensity factor, K, under small scale yielding conditions and provides the intensity of the near crack tip stresses under elastic-plastic conditions. The paper also discusses two issues linked to the numerical modelling of residual stress crack problems-the introduction of a residual stress field into a finite element model and the introduction of a crack into a residual stress field.     

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.     

鱼雷命中后舰船的载荷计算和剩余强度评估

以某舰船为例，计算了鱼雷在舰船底部非接触爆炸使舰体结构产生破损后由于进水引起的浮态和载荷变化，给出了鱼雷命中破损后波浪弯矩随不同破损部位、不同进水体积的变化规律．计算了破损舰船的弹塑性极限弯矩，并对舰船的剩余强度进行了评估．计算结果表明，鱼雷命中的最危险位置是船中，外载荷的增大和结构承载能力的减小使舰体结构在单发命中时也可能失效．     

加载循环数对2D针刺C/SiC复合材料疲劳剩余强度的影响

为研究陶瓷基复合材料的低周疲劳失效机理,通过试验和细观分析对其疲劳特性进行了探讨。研究了室温下加载循环数对2D针刺C/SiC复合材料拉-拉疲劳剩余强度的影响,并采用光学显微镜和扫描电子显微镜对该材料的断口形貌和微观结构进行了观察。结果表明:2D针刺C/SiC复合材料具有较好的抗疲劳特性,在85%极限拉伸强度(UTS)载荷下的循环数超过106;随着加载循环数的增加,剩余强度先增大然后下降。断口分析表明:纤维拔出长度随着加载循环数的增加而增加,说明在疲劳加载过程中,纤维/基体的界面结合强度降低,减缓了材料内部受力的不均匀性,提高了材料的承载能力,使2D针刺C/SiC复合材料出现了疲劳强化现象。      

基于人工神经网络的多处损伤加筋板剩余强度预测

用BP神经网络算法对多处损伤加筋板的剩余强度数据进行训练学习,将预测值和3种经典分析方法的计算值与实验值进行对比,结果表明,ANN法预测值与实验值吻合得最好,LMC修正法和WSU3修正法次之,Swift塑性区连通法最差。最后用所建立的BP网络对不同主裂纹半长和韧带长度的剩余强度进行了预测,结果发现,在其他参数不变的情况下,不管是双筋条还是三筋条加筋板,剩余强度总是随主裂纹半长的增加而成线性降低,随韧带长度的增加而成线性增加,但双筋条加筋板比三筋条加筋板对主裂纹半长和韧带长度的变化更加敏感。     

纤维对超高性能混凝土残余强度及高温爆裂性能的影响

采用普通原材料制备56 d龄期抗压强度为140~160 MPa的空白组超高性能混凝土、钢纤维超高性能混凝土及混杂纤维超高性能混凝土,测定其遭受高温作用后的残余抗压强度和劈裂抗拉强度,并对100%含湿量的混凝土试块进行高温爆裂试验。此外,测定大小2种加热速率对超高性能混凝土高温爆裂行为的影响。结果表明:所配制混凝土的残余抗压强度均随着目标温度的升高呈现先增大再降低的趋势,800℃高温后的残余抗压强度约为常温强度的30%。钢纤维与混杂纤维混凝土的残余劈裂抗拉强度亦呈现先升高再降低的趋势,800℃高温后的残余劈裂抗拉强度分别为常温强度的15.1%和35.4%。空白组混凝土的残余劈裂抗拉强度随着目标温度的升高而单调下降,800℃高温后的强度值约为常温强度的20.3%。7.5℃/min加热速率下,100%含湿量的3种混凝土试块均发生了严重高温爆裂,单掺钢纤维可以改善超高性能混凝土的高温爆裂,但不能避免爆裂的发生,而混杂纤维对超高性能混凝土高温爆裂的改善效果并未显著优于钢纤维。2.5℃/min加热速率下,混杂纤维可避免部分超高性能混凝土试块发生爆裂。      

Fatigue resistance and residual strength of riveted joints in FML

Static and fatigue tests have been carried out on 190-mm-wide fibre metal laminate (FML) riveted lap joints. The specimens were made with a Glare 3-3/2-0.3 material, i.e. a laminate composed of three layers of 2024-T3 aluminium alloy, thickness 0.3 mm and two double layers (0/90) of pre-preg FM-94-27%-S2 glass fibre. Seven configurations were tested which differed in the number of rivet rows (two or three), in the rolling direction of metal layers (perpendicular or parallel to the load direction), in the rivet type (solid or special, such as Hi-Lok or Lock-Bolt), in the rivet material for solid rivets (7050-T73 or 2017-T3), in the rivet diameter (4.8 or 5.5 mm) and in the presence of interlaminar doublers in the overlap area (titanium, aluminium, glass fibre). An additional difference was in the pre-formed rivet head: solid rivets had countersunk head, while Hi-Loks and Lock-Bolts had protruding head. The fatigue tests demonstrated the efficiency of a selective local reinforcement in the overlap area; in some cases, the fatigue resistance was so high that fatigue cracks nucleated in the laminates, rather than in the overlap area, as commonly expected.     

含雷击热-力耦合损伤复合材料层压板拉伸剩余强度预测

为了对含雷击热-力耦合损伤复合材料层压板的剩余强度进行预测,基于连续介质损伤力学法(CDM)和唯象分析法,建立了表征复合材料雷击热-力耦合损伤的刚度矩阵渐进损伤退化模型。基于该模型,通过ABAQUS有限元仿真软件,建立了含雷击热-力耦合损伤的复合材料层压板结构三维模型。结合UMAT子程序,完成了拉伸载荷下的剩余强度预测。结果表明:通过与试验对比,仿真结果与试验结果取得了良好的一致性。本文所建立模型,能够有效进行含雷击热-力耦合损伤复合材料层压板结构拉伸剩余强度预测。     

复合材料加筋板低速冲击损伤及剩余压缩强度试验研究

采用落锤法对复合材料加筋板进行了低速冲击损伤（LVI）试验,根据复合材料加筋板构型,设计了冲击支持支架,研究了支持支架的间距对冲击结果的影响;用相同的冲击能量对复合材料加筋板结构中3处典型位置进行冲击,得到不同位置的损伤形貌;分别对完好件和损伤试验件进行压缩试验,将试验结果进行对比,分析不同位置的冲击损伤对结构压缩性能的影响。试验结果表明：在相同的冲击能量下,支持支架间距越小,所造成的冲击损伤越严重;在50 J冲击能量下,筋条区蒙皮处的冲击所造成的损伤不易观察,筋条间蒙皮处的冲击所造成的损伤最为明显,而筋条边缘蒙皮处的冲击可以导致筋条边缘的脱粘;冲击损伤会使加筋板屈曲载荷轻微下降,筋条间蒙皮和筋条区蒙皮冲击损伤对压缩结果影响相对较小,筋条边缘处的冲击会引起损伤处蒙皮的子层屈曲,并影响结构破坏形式,使结构压缩承载能力有较为明显的下降。     

Fatigue strength prediction of carburized 12Cr steel alloy: Effects of evaluation of maximum crack sizes and residual stress distribution

Axial loading fatigue tests of carburized 12Cr steel alloy in long‐life regime were performed under stress ratios of ?1 and 0. Fatigue fracture can be divided into surface failure, interior failure without fine granular area (FGA), and interior failure with FGA. By considering the effects of the tensile limit, the evaluation of maximum crack sizes (inclusion sizes and FGA sizes), and residual stress distribution, the fatigue strength prediction model of carburized 12Cr steel alloy for inclusion‐FGA‐fisheye induced failure in low stress level region can be established. By comparing the predicted results evaluated by generalized extreme values (GEV) with generalized Pareto (GP), the GP distribution is more suitable to predict the fatigue limit of the carburized 12Cr steel alloy. Furthermore, by using the relationship between inclusion sizes and FGA sizes, the fatigue limit prediction model for the design of components can be established, and the result is extremely accurate for the carburized 12Cr steel alloy.     

Exact and variational theorems for fracture mechanics of composites with residual stresses, traction-loaded cracks, and imperfect interfaces

By partitioning the total stresses in a damaged composite into either mechanical and residual stresses or into initial and perturbation stresses, it was possible to derive several exact results for the energy release rate due to crack growth. These general results automatically include the effects of residual stresses, traction-loaded cracks, and imperfect interfaces. The exact energy release rate results were expressed in terms of exact solutions to reduced composite stress analysis problems. By considering the common situation where the initial stresses are known exactly, but the perturbation stresses are only known approximately, it was possible to derive rigorous upper and lower bounds to the energy release rate for crack growth. Some of the new fracture mechanics equations were applied to crack closure calculations, to fiber fracture and interfacial debonding in the fragmentation test, and to microcracking in composite laminates.     

Development of residual cutting tool life prediction algorithm by processing on CNC machine tool

The paper is dedicated to the decision of a problem of cutting tool diagnostics and working out of a remaining cutting tool life prediction algorithm. The example for practical realization of such algorithm on the CNC machine tool by machining under specified conditions is given. The question of working error compensation by means of corrective adjustment is considered.     

Effect of fibre/matrix adhesion on residual strength of notched composite laminates

Effects of fibre/matrix adhesion and residual strength of notched polymer matrix composite laminates (PMCLs) and fibre reinforced metal laminates (FRMLs) were investigated. Two different levels of adhesion between fibre and matrix were achieved by using the same carbon fibres with or without surface treatments. After conducting short-beam shear and transverse tension tests for fibre/matrix interface characterisation, residual strength tests were performed for PMCLs and FRMLs containing a circular hole/sharp notch for the two composite systems. It was found that laminates with poor interfacial adhesion between fibre and matrix exhibit higher residual strength than those with strong fibre/matrix adhesion. Major failure mechanisms and modes in two composite systems were studied using SEM fractography. The effective crack growth model (ECGM) was also applied to simulate the residual strength and damage growth of notched composite laminates with different fibre/matrix adhesion. Predictions from the ECGM were well correlated with experimental data.     

Residual strength of unidirectional fibre-metal laminates based on JC toughness of C(T) and SE(B) specimens: comparison with M(T) test results

Fibre‐metal laminates (FMLs) are structural composites designed with the aim of producing very low fatigue crack‐propagation rate, damage‐tolerant and high‐strength materials, if compared to aeronautical Al alloys. Their application in aeronautical structures demands a deep knowledge of a wide set of mechanical properties and technological values, including both fracture toughness and residual strength. The residual strength of FMLs have been traditionally determined by using wide centre‐cracked tension panels M(T). The use of this geometry requires large quantities of material and heavy laboratory facilities. In this work, fracture toughness ( J_C) of some unidirectional FMLs laminates was measured using a recently proposed methodology for critical fracture toughness evaluation on compact tension C(T) and single‐edge bend SE(B) specimens. Additionally, residual strength values of wider M(T) specimens with different widths (W from 150 to 200 mm) and several crack to width ratios (2a/W) were experimentally obtained. Some experimental residual strength values of M(T) specimens (W from 150 to 400 mm and different 2a/W ratios) of Arall were also obtained from the bibliography. Based on J_C results from C(T) and SE(B) specimens, and either using or not using crack‐tip plasticity corrections, the residual strengths of the M(T) specimens were predicted and compared to the experimental ones. The results showed good agreement, especially when crack‐tip plasticity corrections were applied.     

Residual strength at −40 °C of a precracked cold‐formed rectangular hollow section made of ultra‐high‐strength steel – an engineering approach

This study investigated the residual strength of a precracked cold‐formed rectangular hollow section made of novel ultra‐high‐strength steel. The primary goal was to experimentally discover the residual strength of the structure when used in low temperature service conditions. The secondary goal was to predict the residual strength by using a J‐integral approach with nonlinear finite element calculations and to compare these predictions with measured results. The experimental tests were carried out with a beam in four‐point bending loading. The test specimens were taken from a cold‐formed rectangular hollow section fabricated from direct quenched (untempered) ultra‐high‐strength steel S960 QC omitting the annealing in the fabrication process. The tests for final failure were carried out at ?40 °C, with the exception of the first pilot test. There were two kinds of tests: (1) the beam was cyclically loaded until the final fracture or the fatigue precrack was first introduced and (2) the specimen was then subjected to a quasistatic bending loading condition until it failed. The new experimental results matched well with our predictions, and both confirmed the high toughness of ultra‐high‐strength steel in beam construction studied, even at a low ambient temperature.     

各向异性复合材料开孔板拉伸强度预测及模型验证

基于有限断裂力学方法建立了一种预测多向复合材料开孔板拉伸强度的通用和半经验模型。该模型同时采用基于应力形式的失效准则和基于能量形式的失效准则预测失效。模型仅需铺层弹性常数、无缺口层合板的强度以及0°铺层的断裂韧性等参数。基于线弹性断裂力学建立了多向复合材料层合板的断裂韧性与0°铺层断裂韧性之间的关系, 进而预测了任意铺层复合材料开孔板发生纤维主导拉伸失效时的强度。将模型预测结果与开孔板拉伸强度的试验数据进行了对比验证, 预测误差最大为9.7%, 与点应力和平均应力等方法的对比表明, 该模型的预测精度高于传统的特征长度方法。      

Microdebonding investigation of the effects of thermal residual stress on the bond strength of a graphite/polymide composite

The microdebonding test was used to investigate the effects of thermal residual stresses resulting from different lay-ups in fabrication on the fiber/matrix bond strength of a graphite-fiber-reinforced polyimide composite. This was accomplished by comparing the results of a cross-plied laminate with those of a unidirectional laminate. The results indicated that the measured interfacial bond strength of the unidirectional composites was greater than that of the cross-plied laminate. The thermal radial stress distribution around the fiber for the unidirectional and the [0₂, 90₂]_s laminates were estimated, to explain this reduction of the interfacial bond strength.     

交变载荷对CFRP复合材料-铝合金粘接接头剩余强度的影响

为了给碳纤维增强聚合物（CFRP）复合材料粘接结构的安全设计及应用提供参考,针对CFRP复合材料-铝合金对接接头,研究了拉-拉交变载荷作用下的疲劳寿命特性及剩余强度变化规律。设计专用夹具,完成接头的制作及固化,并测试其拉伸、剪切准静态失效强度,在此基础上进行不同载荷水平下的疲劳寿命测试。选取特定载荷水平,测试不同循环次数后的接头剩余强度,并对失效形式进行观察分析。结果表明:CFRP复合材料-铝合金对接接头强度-寿命（S-N）曲线在单对数坐标上符合线性函数规律;随着交变载荷循环周期的增加,接头剩余强度呈先慢后快的下降趋势,而且在较大的载荷水平下,下降幅度更为明显;经历交变载荷循环前、后接头失效形式发生改变,由局部CFRP复合材料表层撕裂转变为局部界面破坏。结合试验测试所获得的初始失效准则,并引入疲劳退化因子,建立内聚力模型对交变载荷作用下的粘接接头强度衰减进行数值模拟,结果表明所建立模型能够有效预测交变载荷作用下的接头剩余强度。