Geometrical analysis and pattern recognition using mapping technologies of three-dimensional fracture surfaces in materials

Geometrical analysis of fracture surfaces in materials was made using newly developed computer programs on the three-dimensional images reconstructed by the stereo matching method. The global value of the fractal dimension of the fracture surface was estimated by the box-counting method on a fatigue fracture surface of a Cu-Be alloy and impact fracture surfaces of a SiC and an alumina. The results of the present analysis were well correlated with those of the two-dimensional fractal analysis. The fractal dimension map (FDM) by the box-counting method and the surface roughness map (SRM) proposed in this study can give important information about the local fracture mechanisms, the crack growth direction or the fracture origin in materials. FDM and SRM have interesting characteristics by which one can discriminate the flat regions, the regions of complex geometry or the steeply inclined areas on a given fracture surface. Pattern recognition using mapping technologies of FDM and SRM is also applicable to the extraction of “hidden patterns” on fracture surfaces, which cannot be observed only by microscopes.     

Fractal aspects of ductile and cleavage fracture surfaces

The aim of this paper is to evaluate and interpret the three-dimensional variational fractal dimension of a ductile and a cleavage fracture surface. The fracture surface is acquired by fracturing Charpy impact and static loaded specimens of a low alloy steel in ductile-to-brittle transition temperature range, and reconstructed by a stereoscopic technique. The three-dimensional variational method for measuring fractal dimension is improved by shifting algorithm and tested on the Takagi surface using the local fractal dimension. We find very good fractal behaviour in the ductile area, however, fractal characteristics in the cleavage area are less noticeable. The results are discussed in thermodynamical terms and promote the idea that fractal behaviour reflects the quasi-static process and that the fracture mechanisms in the ductile fracture are independent of strain rate (at least up to 10³ s⁻¹).     

The stress analysis method for three-dimensional composite materials

This study proposes a stress analysis method for three-dimensionally fiber reinforced composite materials. In this method, the rule-of mixture for composites is successfully applied to 3-D space in which material properties would change 3-dimensionally. The fundamental formulas for Young's modulus, shear modulus, and Poisson's ratio are derived. Also, we discuss a strength estimation and an optimum material design technique for 3-D composite materials. The analysis is executed for a triaxial orthogonally woven fabric, and their results are compared to the experimental data in order to verify the accuracy of this method. The present methodology can be easily understood with basic material mechanics and elementary mathematics, so it enables us to write a computer program of this theory without difficulty. Furthermore, this method can be applied to various types of 3-D composites because of its general-purpose characteristics.     

A hybrid boundary element method for three-dimensional fracture analysis

At first, a hybrid boundary element method used for three-dimensional linear elastic fracture analysis is established by introducing the relative displacement fundamental function into the first and the second kind of boundary integral equations. Then the numerical approaches are presented in detail. Finally, several numerical examples are given out to check the proposed method. The numerical results show that the hybrid boundary element method has a very high accuracy for analysis of a three-dimensional stress intensity factor.     

Fractal analysis of rubber wear surfaces and debris

The wear surface and debris of three rubber compounds (NR, PBD and NR/PBD/SBR), worn on a modified blade abrader, were fractal. The fractal dimension of the wear surface was: (1) limited to a finite range, and if the wear mechanism remained the same; (2) independent of the wear load; and (3) the basis for creating a master fractal plot by a shift factor that (4) decreased linearly with wear load. The fractal dimension of wear was determined on the basis of profilometer traces and showed that the wear load affected the scale of the wear process. The fractal dimension of the debris also increased with the wear load and is thought to be a function of the agglomeration mechanism during wear.     

Fractal dimensions for fatigue fracture surfaces performed on micro- and meso-scale levels

A methodology was developed to use digital photograph fracture for calculating the integral fractal dimension and spectrum fractal dimensions for two perpendicular directions. The fractal dimension value, which was discovered by the variation of the pixel size up until the fractal dimension became unchangeable, i.e., where d _\min,d _\max are the borders of the scale level used. The effectiveness of the methodology performed showed the basis of the fracture surface analyses for Al-based alloys BS L65 and 2024 T351 (analogous to Al alloy D16T), specimens of which were tested by pull-push with imitation fretting corrosion damage of the sur- face and with four-point bending after the laser peening, respectively.     

Fractal dimensions for fatigue fracture surfaces performed on micro- and meso-scale levels

A methodology was developed to use digital photograph fracture for calculating the integral fractal dimension and spectrum fractal dimensions for two perpendicular directions. The fractal dimension value, which was discovered by the variation of the pixel size up until the fractal dimension became unchangeable, i.e., where d _\min,d _\max are the borders of the scale level used. The effectiveness of the methodology performed showed the basis of the fracture surface analyses for Al-based alloys BS L65 and 2024 T351 (analogous to Al alloy D16T), specimens of which were tested by pull-push with imitation fretting corrosion damage of the sur- face and with four-point bending after the laser peening, respectively.     

Fractal analysis of the evolution of friction surfaces of galvanic AuNi coatings

Evolution of the surface morphology of galvanic AuNi coatings in the course of tribological tests under dry friction conditions has been studied by atomic force microscopy (AFM). It is shown that fractal analysis of the AFM data provides adequate numerical characterization of the friction surface evolution at various stages of testing.     

Boundary-integral equations and the boundary-element method for three-dimensional fracture mechanics

In this paper, the displacement-discontinuity fundamental solutions for three-dimensional fracture mechanics are obtained by an integral-transform method and the boundary-integral equations are established. By using finite-part integrals, the displacement-discontinuity boundary-element method is realized. Finally, two simple numerical exaamples are given.     

An extended element free Galerkin method for fracture analysis of functionally graded materials

An extended element free Galerkin method (XEFGM) has been adopted for fracture analysis of functionally graded materials (FGMs). Orthotropic enrichments functions are used along with the sub-triangle technique for enhancing the Gauss quadrature accuracy near the crack, and the incompatible interaction integral method is employed to calculate the stress intensity factors. Numerical simulations have proved that XEFGM provides more accurate results by less number of nodes (DOFs) in comparison with the unenriched EFGM and other conventional methods for several FGM problems with different crack locations and loadings. The results have been compared with the reference results, showing the reliability, stability, and efficiency of present XEFGM.

Received 9 June 2014 Accepted 17 September 2014.     

A continuum shape sensitivity method for fracture analysis of isotropic functionally graded materials

This paper presents a new continuum shape sensitivity method for calculating mixed-mode stress-intensity factors for a stationary crack in two-dimensional, linear- elastic, isotropic FGMs with arbitrary geometry. The method involves the material derivative concept taken from continuum mechanics, the mutual potential energy release rate, and direct differentiation. Since the governing variational equation is differentiated prior to discretization, resulting sensitivity equations are independent of approximate numerical techniques, such as the finite element method, boundary element method, mesh-free method, or others. The discrete form of the mutual potential energy release rate is simple and easy to calculate, as it only requires multiplication of displacement vectors and stiffness sensitivity matrices. By judiciously selecting the velocity field, the method only requires displacement response in a subdomain close to the crack tip, thus making the method computationally efficient. Seven finite-element based numerical examples, which comprise mode-I and mixed-mode deformations and/or single or multiple interacting cracks, are presented to evaluate the accuracy of the fracture parameters calculated by the proposed method. Comparisons have been made between stress-intensity factors predicted by the proposed method and available reference solutions in the literature, generated either analytically or numerically using various other fracture integrals or analyses. Excellent agreement is obtained between the results of the proposed method and previously obtained solutions. Therefore, shape sensitivity analysis provides an attractive alternative to fracture analysis of cracks in homogeneous and non-homogeneous materials.