THE DAMAGE PROCESS IN A FINITE-SIZED BRITTLE SPECIMEN WITH INTERACTING MICROCRACKS

Abstract— The whole damage process in a finite sized specimen with interacting microcracks is simulated by a method combining the closed form crack solutions with boundary elements. Interactions among microcracks and boundary elements are taken into account with an explicit interaction matrix. A coalescence criterion is assumed to rule the intersection behaviour and propagation arrest. The fatal coalescence cluster resulting in the failure of the specimen, out of many intersections of propagating microcracks, is identified with a particular coalescence matrix. The numerical model proposed in this paper can be used to simulate the damage process in a brittle specimen of any shape, under arbitrary plane stress conditions.     

Effect of Alumina Addition on the Tetragonal-to-Monoclinic Phase Transformation in Zirconia–3 mol% Yttria

The tetragonal-to-monoclinic martensitic phase transformation in ZrO–3 mol% Y₂O₃ (PSZ) containing 0 to 12 wt% Al₂O₃ was investigated by dilatometry, XRD, and SEM-EDS methods. The propagation of the transformation into the specimen interiors was suppressed by the addition of Al₂O₃. The grain size was independent of the addition of Al₂O₃. Both Y₂O₃ and Al₂O₃ segregated at grain boundaries. From this segregation behavior, it was suggested that a certain compound or phase of Y₂O₃–Al₂O₃ could be formed at grain boundaries, which would presumably prevent the propagation of the transformation into interiors of PSZ-containing Al₂O₃.     

Failure criteria for linear elastic materials with U-notches

This paper provides a simple, albeit accurate, criterion for prediction of the rupture loads of brittle, or quasi-brittle, U-notched samples, where linear elastic fracture mechanics is not applicable because blunted notches do not exhibit stress singularities. Good agreement is found between numerical predictions and experimental results. The results of fracture tests from 18 different ceramic materials and a polymer (at − 60°C) are summarized and are used as a reference for checking the fracture criterion. Seven fracture criteria are reviewed and it is shown that all can be recast into the proposed criterion.     

沿晶渗碳体网断裂机制的研究

对轴承钢研磨裂纹的成因和消除途径进行了研究,渗碳体层越厚,越容易产生研磨裂纹。控制好终轧温度和轧后冷速,使之不形成较厚的Fe3C网,可以防止研磨裂纹的产生。     

Application of adhesively bonded single lap joints for fracture assessment of adhesive materials

In this study, a method has been proposed to obtain the failure envelope of brittle adhesives using the experimental failure loads of precracked single lap joints (SLJs). The proposed technique is based on the principles of linear elastic fracture mechanics (LEFM), on J-integral relations, and on results of a numerical analysis. Compared to the previous approaches, the introduced experimental method has some advantages such as low manufacturing costs and simpler test procedure. The proposed method can also provide a wide range of mode mix ratios without the need of an additional apparatus. The fracture envelope obtained from the proposed method was then verified by performing some fracture tests including double cantilever beam (DCB), end-notched flexure (ENF), and single leg bending (SLB) specimens. Good correlation was seen between the fracture envelopes of the proposed method and the ones obtained from the fracture mechanics experiments.     

Damage formation and suppression in rotary ultrasonic machining of hard and brittle materials: A critical review

Rotary ultrasonic machining (RUM) combines diamond grinding with small-amplitude tool vibration, to improve machining processes of hard and brittle materials. It has been successfully applied to the machining of a number of brittle materials from optical glasses to advanced ceramics as well as ceramic matrix composites. The emphasis of this literature review was on formation mechanism and suppression methods of machining induced damages that truly limit RUM machining efficiency improvement of brittle materials. In this review paper, material removal mechanism and cutting force modeling of RUM of brittle materials were presented, as well as all corresponding roles in the damage formation process. The critical processing capacity of RUM machine tools was described, which guarantees the RUM effectiveness and consequently constitutes the boundary condition of processing parameters determination. Formation mechanisms of edge chipping, tearing defects, subsurface damages, and their interactive effects were summarized. Advances in damage suppression methods were also described, including optimization of processing parameters, tool design of low damage, and other methods such as rotary ultrasonic elliptical machining.     

脆性材料磨削加工损伤及工件强度研究

通过对脆性材料磨削加工损伤机理的分析,说明磨削方向与脆性材料强度分布的各向异性有关.提出一种外圆磨床磨削圆柱类脆性材料的运动模式,并对磨削加工试件进行强度试验、Weibull统计分析和断口显微分析,结果表明对于外圆磨削,改变磨削加工方向,脆性材料工件的轴向抗拉强度可以提高30%.     

Development of diamond-like carbon fibre wheel

The first author invented a unique diamond-like carbon (DLC) grinding wheel, in which the DLC fibres were made by rolling Al sheets coated with DLC films and aligned normally to the grinding wheel surface by laminating Al sheets together with DLC fibres [K. Yamaguchi, Y. Wei, M. Takeuchi, Development of DLC fibre grinding wheel, in: Proceedings of the Vernal Meeting of the JSPE, Tokyo, 16–18 March 1999, p. 260]. In this paper, the formation process of DLC fibres and the fabrication process of a DLC fibre wheel were investigated. Many grinding experiments were also carried out on a precision NC plane milling machine using a newly developed DLC wheel. Grinding of specimens of silicon wafers, optical glasses, quartz, granites and hardened die-steel SKD11 demonstrated the capabilities to nanometer surface finish. A smooth surface with a roughness value of Ra 2.5 nm (Ry 26 nm) was achieved.     

Elastic-plastic-brittle transitions of potassium dihydrogen phosphate crystals: characterization by nanoindentation

Potassium dihydrogen phosphate (KDP) crystals are widely used in laser ignition facilities as optical switching and frequency conversion components. These crystals are soft, brittle, and sensitive to external conditions (e.g., humidity, temperature, and applied stress). Hence, conventional characterization methods, such as transmission electron microscopy, cannot be used to study the mechanisms of material deformation. Nevertheless, understanding the mechanism of plastic-brittle transition in KDP crystals is important to prevent the fracture damage during the machining process. This study explores the plastic deformation and brittle fracture mechanisms of KDP crystals through nanoindentation experiments and theoretical calculations. The results show that dislocation nucleation and propagation are the main mechanisms of plastic deformation in KDP crystals, and dislocation pileup leads to brittle fracture during nanoindentation. Nanoindentation experiments using various indenters indicate that the external stress fields influence the plastic deformation of KDP crystals, and plastic deformation and brittle fracture are related to the material’s anisotropy. However, the effect of loading rate on the KDP crystal deformation is practically negligible. The results of this research provide important information on reducing machining-induced damage and further improving the optical performance of KDP crystal components.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00320-3