Bending-stretching analysis of thick functionally graded micro-plates using higher-order shear and normal deformable plate theory

In the present article, higher-order shear and normal deformable plate theory together with modified couple stress theory are developed to study the bending analysis of thick functionally graded rectangular micro-plates. One material length scale parameter is used for capturing the size effects. Utilizing the variational approach and also a principle of virtual displacement, a new form of equilibrium equations and the corresponding boundary conditions are derived. It is assumed that material properties vary through the thickness according to the power law function. Finally, an analytical solution for the bending problem of a simply supported FG rectangular micro-plate is presented.     

Weight function,stress intensity factor and crack opening displacement solutions to periodic collinear edge hole cracks

Periodic collinear edge hole cracks and arbitrary small cracks emanating from collinear holes, which are two typical multiple site damages occurred in the aircraft structures, are studied by using the weigh function method. An explicit closed form weight function for periodic edge hole cracks in an infinite sheet is obtained and further used to calculate the stress intensity factor and crack opening displacement for various loading cases. Compared to finite element method, the present weight function is accurate and highly efficient. The interactions of the holes and cracks on the stress intensity factor and crack opening displacement are quantitatively determined by using the present weight function. An approximate weight function method is also proposed for arbitrary small cracks emanating from multiple collinear holes. This method is very useful for calculating the stress intensity factor for arbitrary small cracks.     

Low cycle fatigue life prediction in shot‐peened components of different geometries—part I: residual stress relaxation

In this study, the residual stress relaxation behaviour occurring during low‐cycle fatigue in shot‐peened specimens with either a flat or a notched geometry has been studied. A representative low‐pressure steam turbine material, FV448, was used. The residual stress and strain hardening profiles caused by shot peening were measured experimentally and were then incorporated into a finite element model. By allowing for both effects of shot peening, the residual stress relaxation behaviour was successfully simulated using this model and correlated well with the experimental data. Although more modelling work may be required to simulate the interaction between shot peening effects and external loads in a range of notched geometries, the model predictions are consistent with the specimens tested in the current study. The novelty of this study lies in the development of such a modelling approach which can be used to effectively simulate the complex interaction between shot peening effects and external loads in notched regions. Compared with the un‐notched geometry, the notched geometry was found to be more effective in retaining the improvement in fatigue life resulting from shot peening, by restricting the compressive residual stress relaxation during fatigue loading.     

Evaluation of dynamic fracture toughness parameters of locomotive axle steel by instrumented Charpy impact test

The analysis of the energy of fracture of specimens from steel OSL, which is widely used for the manufacture of railway axles under shock loading, is performed. The nature and quantitative parameters of the typical stages of the processes of plastic and brittle fracture, depending on the test temperature and stiffness of the stress state at the tip of the crack‐like defect, are established. It is shown that impact loading at 20 °C leads to the formation of the local zone of plasticity and ductile–brittle fracture of the material. An increased stiffness of the stress state at the tip of the defect at ?40 °C causes brittle fracture. An approach is developed, which is based on using the size of shear lips as a quantitative parameter of fracture under normal and low temperatures, similar in its physical essence to deformation approaches of nonlinear fracture mechanics. Based on this approach and the quantitative analysis of specimen fracture zones, the physical and mechanical scheme of specimen fracture is proposed in the presence of localized plasticity and in its absence near the tip of the concentrator.     

Non-local line method for notched elements with use of effective length calculated in an elasto-plastic condition

The paper presents a non-local line method used to the fatigue life calculation of notched elements. The presented method is based on the concept of an effective length which determines the size of the equivalent fatigue zone. Effective values of normal stress calculated in the critical plane with a weight function were applied when determining the equivalent fatigue zone. Simulation studies were performed for two types of steel and two types of loading. Five different series of tests and simulations were used. Experimental studies were carried out for 40 HM-T and EA4T steels. These materials are used in railway industry, including the manufacturing of coupling bars. The notched test specimens contained notches with a tip radius of 0.2, 0.5, 0.8 and 1 mm. Stress calculations were performed using the finite element method by adopting cyclic material properties described by the model of a multi-linear hardening. Non-local calculations were performed in a defined critical plane for normal stress distribution and a weight function. As a result, the function of variation of the effective length depending on the loading level and geometry of the notch has been determined.     

Fatigue behaviour and modelling of talc‐filled and short glass fibre reinforced thermoplastics,including temperature and mean stress effects

Effects of temperature and mean stress on fatigue behaviour of talc‐filled polypropylene (PP‐T) and short glass fibre reinforced polypropylene (PP‐G), polyamide‐66 (PA66), and a blend of polyphenylene ether and polystyrene (PPE/PS) were investigated. Load‐controlled fatigue tests were conducted under positive stress ratios (R = 0.1 and 0.3) and at several temperatures (T = 23, 85 and 120 °C). Larson–Miller parameter was used and a shift factor of Arrhenius type was developed to correlate fatigue data at various temperatures. Effect of mean stress on fatigue life was significant for some of the studied materials; however, for the PPE/PS blend no effect of mean stress was observed. Modified Goodman and Walker mean stress equations were evaluated for their ability to correlate mean stress data. A general fatigue life prediction model was also used to account for the effects of mean stress, temperature, anisotropy and frequency.     

An investigation of T‐stresses in a plate with an inclined crack under biaxial loadings

For plates with an inclined crack of wide‐range aspect ratios under biaxial loadings, T‐stress values are calculated with three‐dimensional finite element method. The results show that the normalized T‐stress is crack length and orientation dependent. A linear equation for the relationship between normalized T‐stresses and biaxility factors is proposed to describe the normalized T‐stresses for different crack lengths and crack angles under different biaxial loadings, which is more convenient and involves wider biaxility ratios compared with the existing solutions. The plate thickness effect and the trend of normalized T‐stresses along the crack front thickness are also studied for mode I and I–II mixed‐mode cracks. Based on the analyses and comparisons, it is necessary to take the thickness effect into consideration when the crack length is long enough (a/W = 7/10). When the component of mode II is significant (β > 45°), and the biaxility ratios are negative, T‐stresses near the free surface are lower than those at other positions, which are the opposite of mode I crack and most of I–II mixed‐mode crack.     

Analytical modelling of residual stress in additive manufacturing

A physics‐based analytical model to assess residual stresses in additive manufacturing made of metallic materials is presented and validated experimentally. The model takes into consideration the typical multi‐pass aspect of additive manufacturing. First, the thermal signature of the process is assessed by predicting the temperature for the problem of a moving heat source, then, the thermally induced stresses in a homogenous semi‐infinite medium are determined. Taking the thermal stresses as input, the residual stresses are calculated analytically to obtain the distribution across the depth. Good agreement is obtained between the analytical prediction and X‐ray measurements made on Selective Laser Melted 316L Stainless Steel. In addition, the analytical approach enables in‐depth interpretations of results with basis in the true mechanisms of the process. Thus, the present model appears as a promising tool for optimization of process parameters in additive manufacturing, which in turn will improve the understanding of process parameters and their effect on properties of the final product.     

3D printing system: an innovation for small-scale manufacturing in home settings? – early adopters of 3D printing systems in China

This study investigates Chinese consumers’ adoption of the innovative 3D printing systems for small-scale manufacturing in home settings. Empirical studies were conducted in a survey with 256 participants. The number of significant determinants that affect an individual’s decision to adopt 3D printing systems has been identified by applying a model that integrates the Technology Acceptance Model and Innovation Diffusion Theory. A number of moderation effects of demographic variables (e.g. gender, design background) on the association between motivational variables and participants’ adoption have also been analysed with factor analysis, structural equation modelling and hierarchical regression. Our results shed some light on the characteristics of early adopters of home 3D printing systems in China. This study contributes to the early understanding of Chinese consumers’ adoption of innovative 3D printing systems.