Pub Date : 2025-03-14DOI: 10.1016/j.engfailanal.2025.109493
Mostafa Gargourimotlagh , Dave Matthews , Simon Schneider , Matthijn de Rooij
Rolling contact fatigue (RCF) failure is a primary life-limiting mechanism in tribological contacts, often driven by microscale phenomena that lead to plastic deformation under cyclic loading. Surface topography and hardness play critical roles in controlling the extent of plastic deformation at and beneath the surface. This study investigates fatigue crack initiation and propagation as influenced by surface machining processes and different hardness levels of the CrMoV steel rolling elements obtained from industrial steel rolls. The obtained results, from a set of RCF tests under identical loading and testing conditions, indicated that fatigue wear is a dominant degradation mechanism and is driven by asperity-level features. Surface topography significantly affects the orientation and location of crack initiation, while the hardness and the evolution of surface features during testing influence the rate of crack propagation. A comparison of the propagation rates across different hardness levels revealed an optimal hardness ratio at which fatigue damage is minimized. The outcomes indicated that crack length dispersion increases as the hardness deviates from the optimal level.
{"title":"Insights in the interaction between roughness reduction and fatigue crack growth in rolling contacts","authors":"Mostafa Gargourimotlagh , Dave Matthews , Simon Schneider , Matthijn de Rooij","doi":"10.1016/j.engfailanal.2025.109493","DOIUrl":"10.1016/j.engfailanal.2025.109493","url":null,"abstract":"<div><div>Rolling contact fatigue (RCF) failure is a primary life-limiting mechanism in tribological contacts, often driven by microscale phenomena that lead to plastic deformation under cyclic loading. Surface topography and hardness play critical roles in controlling the extent of plastic deformation at and beneath the surface. This study investigates fatigue crack initiation and propagation as influenced by surface machining processes and different hardness levels of the CrMoV steel rolling elements obtained from industrial steel rolls. The obtained results, from a set of RCF tests under identical loading and testing conditions, indicated that fatigue wear is a dominant degradation mechanism and is driven by asperity-level features. Surface topography significantly affects the orientation and location of crack initiation, while the hardness and the evolution of surface features during testing influence the rate of crack propagation. A comparison of the propagation rates across different hardness levels revealed an optimal hardness ratio at which fatigue damage is minimized. The outcomes indicated that crack length dispersion increases as the hardness deviates from the optimal level.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109493"},"PeriodicalIF":4.4,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637315","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-14DOI: 10.1016/j.engfailanal.2025.109530
G. Bethel Lulu , Boyang An , Rong Chen , Ping Wang , Yaoliang Sun , Sentayehu Lelisa Diririsa
The evolution of geometric irregularities at rail welds poses a significant challenge to the safety, performance, and maintenance of high-speed railway systems. High-frequency wheel-rail dynamics, induced by wheel polygonization and variations in rail hardness, significantly accelerate the formation and progression of these irregularities. Over time, this leads to damage to both vehicle and track components. This study investigate the initiation and evolution mechanism of rail weld irregularity caused by wheel impacts and rail hardness gradients. The approach integrates vehicle-track dynamics, wheel-rail contact mechanics, and wear modeling. A detailed field measurement campaign was conducted to gather baseline data on rail weld irregularities and wheel surface defects. The model was validated using this field data and subsequently applied to explore the initiation and progression of rail weld irregularities. The role of wheel polygonal wear and the hardness gradient at the weld section are analyzed to elucidate their contributions to pressure distribution and the growth of irregularities. Key factors considered include wheel polygonization, vehicle speed, contact pressure, rail hardness, and the number of vehicle cycles. The results highlight that vehicle speed, wheel defects, and hardness gradients play a critical role in the initiation and evolution of rail weld irregularities in high-speed railway systems.
{"title":"Investigation into the initiation and evolution mechanism of rail weld irregularities due to wheel impacts in High-Speed railways","authors":"G. Bethel Lulu , Boyang An , Rong Chen , Ping Wang , Yaoliang Sun , Sentayehu Lelisa Diririsa","doi":"10.1016/j.engfailanal.2025.109530","DOIUrl":"10.1016/j.engfailanal.2025.109530","url":null,"abstract":"<div><div>The evolution of geometric irregularities at rail welds poses a significant challenge to the safety, performance, and maintenance of high-speed railway systems. High-frequency wheel-rail dynamics, induced by wheel polygonization and variations in rail hardness, significantly accelerate the formation and progression of these irregularities. Over time, this leads to damage to both vehicle and track components. This study investigate the initiation and evolution mechanism of rail weld irregularity caused by wheel impacts and rail hardness gradients. The approach integrates vehicle-track dynamics, wheel-rail contact mechanics, and wear modeling. A detailed field measurement campaign was conducted to gather baseline data on rail weld irregularities and wheel surface defects. The model was validated using this field data and subsequently applied to explore the initiation and progression of rail weld irregularities. The role of wheel polygonal wear and the hardness gradient at the weld section are analyzed to elucidate their contributions to pressure distribution and the growth of irregularities. Key factors considered include wheel polygonization, vehicle speed, contact pressure, rail hardness, and the number of vehicle cycles. The results highlight that vehicle speed, wheel defects, and hardness gradients play a critical role in the initiation and evolution of rail weld irregularities in high-speed railway systems.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109530"},"PeriodicalIF":4.4,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637314","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-13DOI: 10.1016/j.engfailanal.2025.109524
Zhuang Chen , Qingbing Dong , Tongyang Li , Zhongliang Xie , Bo Zhao
In order to enhance the wear resistance of spline couplings, it is necessary to study the impact of crowning modification on wear behavior. The present work conducts ball-on-disc wear experiments to determine the wear coefficient of the spline material. A method is developed to calculate the wear volume of the ball by reconstructing its 3D profile from the 2D boundary of the wear scar. Subsequently, a bilateral wear method based on the Archard wear model is proposed and validated by comparing the ball-on-disc experimental measurements with the simulated results. The method is then applied to a simplified model for splines under various misalignment angles. The results show that the slip path of the nodes on spline forms non-closed loop, and the sliding mode closely resembles a unidirectional sliding. The initial wear rate of the crowned spline is lower than that of the uncrowned spline at a certain misalignment angle, but both regions can reach a similar level of wear rate during the steady stage. The maximum wear depth linearly increases along with the loading cycles during the steady stage, and the wear life is thus predictable based on a fitting equation. Although crowning elongates the wear life of the spline, it is still inadequate to meet the expected service life. Therefore, critical wear coefficients are identified to satisfy the design life requirements and guide material strengthening.
{"title":"Bilateral wear analysis of crowned spline coupling subject to angular misalignment","authors":"Zhuang Chen , Qingbing Dong , Tongyang Li , Zhongliang Xie , Bo Zhao","doi":"10.1016/j.engfailanal.2025.109524","DOIUrl":"10.1016/j.engfailanal.2025.109524","url":null,"abstract":"<div><div>In order to enhance the wear resistance of spline couplings, it is necessary to study the impact of crowning modification on wear behavior. The present work conducts ball-on-disc wear experiments to determine the wear coefficient of the spline material. A method is developed to calculate the wear volume of the ball by reconstructing its 3D profile from the 2D boundary of the wear scar. Subsequently, a bilateral wear method based on the Archard wear model is proposed and validated by comparing the ball-on-disc experimental measurements with the simulated results. The method is then applied to a simplified model for splines under various misalignment angles. The results show that the slip path of the nodes on spline forms non-closed loop, and the sliding mode closely resembles a unidirectional sliding. The initial wear rate of the crowned spline is lower than that of the uncrowned spline at a certain misalignment angle, but both regions can reach a similar level of wear rate during the steady stage. The maximum wear depth linearly increases along with the loading cycles during the steady stage, and the wear life is thus predictable based on a fitting equation. Although crowning elongates the wear life of the spline, it is still inadequate to meet the expected service life. Therefore, critical wear coefficients are identified to satisfy the design life requirements and guide material strengthening.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109524"},"PeriodicalIF":4.4,"publicationDate":"2025-03-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628663","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-13DOI: 10.1016/j.engfailanal.2025.109514
Ning Jianguo , Zhang Zhaohui , Wang Jun , Wang Lei , Shi Xinshuai , Hu Shanchao
In order to investigate the effect of static fissure on the stress field of anchored rock beams and the axial force of anchors, this paper deduces the differential equation of shear stress at the anchor-rock interface (later called anchor-rock interface) in the anchored rock beams containing static fissure based on the fracture mechanics theory and solves the equation, which is shown in the results: (1) When the anchor-rock interface is within the disturbance range of the fissure tip, the vertical compressive stress at the anchor-rock interface and the shear stress at the anchor-rock interface also have sudden changes, and the magnitude of the sudden change of shear stress at the upper tip of the fissure is larger than that at the lower tip; (2) When the anchor-rock interface is outside the influence range of fissure tip disturbance, the distribution form of vertical stress at the anchor-rock interface and shear stress at the anchor-rock interface is still a smooth curve. (3) For the axial force of bolt, both at the tip of the fissure show a rapid increase in axial force, with the upper tip of the fissure showing a larger increase in bolt axial force than the lower tip.
{"title":"Study on the effect of static fissure on the stress field of anchored rock beam and axial force of bolt","authors":"Ning Jianguo , Zhang Zhaohui , Wang Jun , Wang Lei , Shi Xinshuai , Hu Shanchao","doi":"10.1016/j.engfailanal.2025.109514","DOIUrl":"10.1016/j.engfailanal.2025.109514","url":null,"abstract":"<div><div>In order to investigate the effect of static fissure on the stress field of anchored rock beams and the axial force of anchors, this paper deduces the differential equation of shear stress at the anchor-rock interface (later called anchor-rock interface) in the anchored rock beams containing static fissure based on the fracture mechanics theory and solves the equation, which is shown in the results: (1) When the anchor-rock interface is within the disturbance range of the fissure tip, the vertical compressive stress at the anchor-rock interface and the shear stress at the anchor-rock interface also have sudden changes, and the magnitude of the sudden change of shear stress at the upper tip of the fissure is larger than that at the lower tip; (2) When the anchor-rock interface is outside the influence range of fissure tip disturbance, the distribution form of vertical stress at the anchor-rock interface and shear stress at the anchor-rock interface is still a smooth curve. (3) For the axial force of bolt, both at the tip of the fissure show a rapid increase in axial force, with the upper tip of the fissure showing a larger increase in bolt axial force than the lower tip.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109514"},"PeriodicalIF":4.4,"publicationDate":"2025-03-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637311","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-12DOI: 10.1016/j.engfailanal.2025.109484
Yanan Ke , Chaofeng Han , Baozhong Sun , Xianyan Wu
Failure analysis and real-time damage monitoring is of great significance for evaluating the service life of carbon fiber-reinforced epoxy composites structural parts. However, due to the complex microstructure and heterogeneous properties of composite materials, achieving online damage identification in practical applications remains challenging. In this paper, digital image correlation (DIC) technology is used to analyze the failure mode of 3D angle-interlock woven composites including surface strain, damage types. Combining with deep learning network, a comprehensive system deep learning network is developed for identifying, segmenting and analyzing the surface damage of composite materials. In warp tension, transverse cracks initiate in the resin region, with their width confined between two adjacent warp yarns. In weft tension, only transverse cracks originate at the fiber-resin interface within the surface warp yarns and propagate into the surrounding resin. After training, the YOLOv5x model performs well across all categories, with an especially high accuracy of 0.991 in detecting transverse cracks. The trained YOLOv5x deep learning network was used for skeleton extraction, type identification and quantitative statistics for cracks. The statistical analysis shows that the modulus decrease is related to the cracks, and the damage threshold of the composites remains the same across different aging periods.
{"title":"Failure analysis and on-line damage monitoring based on deep-learning for thermo-oxidative aged 3D angle-interlock woven composites under tension","authors":"Yanan Ke , Chaofeng Han , Baozhong Sun , Xianyan Wu","doi":"10.1016/j.engfailanal.2025.109484","DOIUrl":"10.1016/j.engfailanal.2025.109484","url":null,"abstract":"<div><div>Failure analysis and real-time damage monitoring is of great significance for evaluating the service life of carbon fiber-reinforced epoxy composites structural parts. However, due to the complex microstructure and heterogeneous properties of composite materials, achieving online damage identification in practical applications remains challenging. In this paper, digital image correlation (DIC) technology is used to analyze the failure mode of 3D angle-interlock woven composites including surface strain, damage types. Combining with deep learning network, a comprehensive system deep learning network is developed for identifying, segmenting and analyzing the surface damage of composite materials. In warp tension, transverse cracks initiate in the resin region, with their width confined between two adjacent warp yarns. In weft tension, only transverse cracks originate at the fiber-resin interface within the surface warp yarns and propagate into the surrounding resin. After training, the YOLOv5x model performs well across all categories, with an especially high accuracy of 0.991 in detecting transverse cracks. The trained YOLOv5x deep learning network was used for skeleton extraction, type identification and quantitative statistics for cracks. The statistical analysis shows that the modulus decrease is related to the cracks, and the damage threshold of the composites remains the same across different aging periods.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109484"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143620655","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-12DOI: 10.1016/j.engfailanal.2025.109528
Tao-long Xu , Feng Xiong , Hao-yu Han , Heng Rong , Jun-lei Tang , Hong-ye Jiang , You-lv Li , Yi Liao
Hydrogen energy is increasingly becoming a critical component of China’s energy structure due to its cleanliness, zero carbon emissions, high energy efficiency, and wide availability. Mixing hydrogen with natural gas in specific proportions and transporting it through the existing natural gas pipeline network is widely regarded as an economical and effective method of hydrogen utilization. However, pipeline failure due to hydrogen embrittlement (HE), especially in the girth weld zone, is a major challenge for hydrogen-mixed transportation. This paper investigates the hydrogen permeation behavior in various zones of the girth weld through electrochemical hydrogen permeation tests, elucidating the reasons for differences in hydrogen permeability coefficients and absorbed hydrogen concentrations in each zone. A compact tension (CT) specimen model based on the phase field method (PFM) was developed to simulate and fit the critical energy release rate of the X80 pipeline girth weld zone in a hydrogen environment. From the obtained force–displacement curves, the critical J-integral for each zone in a hydrogen environment was calculated, examining the fracture toughness variations of X80 pipeline steel base metal (BM) and weld metal (WM) under different hydrogen concentration conditions. Additionally, a quarter-pipe model of an X80 pipeline with a crack was developed using a phase field (PF) fracture model coupled with hydrogen diffusion, simulating the hydrogen-induced cracking phenomenon of the pipeline under actual working conditions. The study investigated the effects of internal pipeline pressure, initial hydrogen concentration, crack geometry, and defect types on the hydrogen concentration distribution at the crack tip and the PF value. Results indicated that before crack propagation, increasing internal pipeline pressure raised the hydrogen concentration at the crack tip, whereas after crack initiation, the hydrogen concentration at the crack tip decreased; increasing initial hydrogen concentration exacerbated the performance degradation of the girth weld zone; the sharper the crack geometry, the higher the hydrogen concentration at the crack tip and the more severe the damage at the crack tip. The models and analytical methods established in this study provide a theoretical basis and technical support for predicting and assessing the safety of pipelines under actual operating conditions. The research findings can guide and inform the design of safer hydrogen-mixed transportation systems.
{"title":"Research on hydrogen-induced crack propagation behavior in the girth weld zone of X80 hydrogen-enriched pipelines based on the phase field method","authors":"Tao-long Xu , Feng Xiong , Hao-yu Han , Heng Rong , Jun-lei Tang , Hong-ye Jiang , You-lv Li , Yi Liao","doi":"10.1016/j.engfailanal.2025.109528","DOIUrl":"10.1016/j.engfailanal.2025.109528","url":null,"abstract":"<div><div>Hydrogen energy is increasingly becoming a critical component of China’s energy structure due to its cleanliness, zero carbon emissions, high energy efficiency, and wide availability. Mixing hydrogen with natural gas in specific proportions and transporting it through the existing natural gas pipeline network is widely regarded as an economical and effective method of hydrogen utilization. However, pipeline failure due to hydrogen embrittlement (HE), especially in the girth weld zone, is a major challenge for hydrogen-mixed transportation. This paper investigates the hydrogen permeation behavior in various zones of the girth weld through electrochemical hydrogen permeation tests, elucidating the reasons for differences in hydrogen permeability coefficients and absorbed hydrogen concentrations in each zone. A compact tension (CT) specimen model based on the phase field method (PFM) was developed to simulate and fit the critical energy release rate of the X80 pipeline girth weld zone in a hydrogen environment. From the obtained force–displacement curves, the critical <em>J</em>-integral for each zone in a hydrogen environment was calculated, examining the fracture toughness variations of X80 pipeline steel base metal (BM) and weld metal (WM) under different hydrogen concentration conditions. Additionally, a quarter-pipe model of an X80 pipeline with a crack was developed using a phase field (PF) fracture model coupled with hydrogen diffusion, simulating the hydrogen-induced cracking phenomenon of the pipeline under actual working conditions. The study investigated the effects of internal pipeline pressure, initial hydrogen concentration<sub>,</sub> crack geometry, and defect types on the hydrogen concentration distribution at the crack tip and the PF value. Results indicated that before crack propagation, increasing internal pipeline pressure raised the hydrogen concentration at the crack tip, whereas after crack initiation, the hydrogen concentration at the crack tip decreased; increasing initial hydrogen concentration exacerbated the performance degradation of the girth weld zone; the sharper the crack geometry, the higher the hydrogen concentration at the crack tip and the more severe the damage at the crack tip. The models and analytical methods established in this study provide a theoretical basis and technical support for predicting and assessing the safety of pipelines under actual operating conditions. The research findings can guide and inform the design of safer hydrogen-mixed transportation systems.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109528"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628662","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-12DOI: 10.1016/j.engfailanal.2025.109525
Jiacheng Shen , Yu Pan , Jianyong Zuo
The wheel-mounted brake disc is a critical component of the high-speed train brake system, and the bolt hole is identified as a high-risk region for fatigue failure in practice. This study proposes a thermal fatigue damage analysis method incorporating the multiaxial stress state to explore the complex failure mechanisms for wheel-mounted brake discs. A finite element model of a typical wheel-mounted brake disc is established and validated for a closer-to-reality prognostication. The thermodynamic response of the brake disc during emergency braking is analyzed, and the fatigue life of the critical nodes is predicted based on the multiaxial stress state. The results reveal that the multiaxial stress in the bolt-hole region jointly contributes to the formation of fatigue damage, as opposed to being caused by a specific uniaxial one. Additionally, the evolution of fatigue crack propagation is further investigated by simulation analysis. The findings indicate that the propagation in axial is more likely to result in fatigue failure, compared to the radial direction. This study is supposed to provide insights into the mechanisms of thermal fatigue damage in wheel-mounted brake discs and offer guidance for the structural design of critical brake components as well as the development of effective maintenance strategies.
{"title":"Study on thermal fatigue damage mechanisms for high-speed train’s wheel-mounted brake disc considering multiaxial stress state","authors":"Jiacheng Shen , Yu Pan , Jianyong Zuo","doi":"10.1016/j.engfailanal.2025.109525","DOIUrl":"10.1016/j.engfailanal.2025.109525","url":null,"abstract":"<div><div>The wheel-mounted brake disc is a critical component of the high-speed train brake system, and the bolt hole is identified as a high-risk region for fatigue failure in practice. This study proposes a thermal fatigue damage analysis method incorporating the multiaxial stress state to explore the complex failure mechanisms for wheel-mounted brake discs. A finite element model of a typical wheel-mounted brake disc is established and validated for a closer-to-reality prognostication. The thermodynamic response of the brake disc during emergency braking is analyzed, and the fatigue life of the critical nodes is predicted based on the multiaxial stress state. The results reveal that the multiaxial stress in the bolt-hole region jointly contributes to the formation of fatigue damage, as opposed to being caused by a specific uniaxial one. Additionally, the evolution of fatigue crack propagation is further investigated by simulation analysis. The findings indicate that the propagation in axial is more likely to result in fatigue failure, compared to the radial direction. This study is supposed to provide insights into the mechanisms of thermal fatigue damage in wheel-mounted brake discs and offer guidance for the structural design of critical brake components as well as the development of effective maintenance strategies.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109525"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143620660","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-03-12DOI: 10.1016/j.engfailanal.2025.109522
Marco A. Paredes-Gordillo, Inés Iváñez, Shirley K. García-Castillo, Carlos Navarro
This study examines the experimental behaviour of composite structures subjected to high-velocity multiple impact, which is critical in applications where simultaneous impacts from multiple projectiles or debris may occur. This work also investigates the influence of the distance between projectiles on global variables, including the damaged area. Furthermore, a comparison is conducted between single and multiple high-velocity impact. The findings reveal that both the damaged area, the ballistic limit and the residual velocity of the projectiles are significantly affected by the simultaneous multiple impact phenomenon.
{"title":"An experimental study of high-velocity multiple impact on the structural behaviour of GFRP Cross-Ply laminates","authors":"Marco A. Paredes-Gordillo, Inés Iváñez, Shirley K. García-Castillo, Carlos Navarro","doi":"10.1016/j.engfailanal.2025.109522","DOIUrl":"10.1016/j.engfailanal.2025.109522","url":null,"abstract":"<div><div>This study examines the experimental behaviour of composite structures subjected to high-velocity multiple impact, which is critical in applications where simultaneous impacts from multiple projectiles or debris may occur. This work also investigates the influence of the distance between projectiles on global variables, including the damaged area. Furthermore, a comparison is conducted between single and multiple high-velocity impact. The findings reveal that both the damaged area, the ballistic limit and the residual velocity of the projectiles are significantly affected by the simultaneous multiple impact phenomenon.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109522"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628664","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Robot structures made of steel or aluminum tend to be heavy and can undergo significant deformation, which leads to increased power consumption and a higher risk of failure under load conditions. Therefore, it is essential to create lighter-weight structures without compromising the performance of the robot. Taguchi methods can be employed to design these lightweight robot structures and optimize their performance. Additionally, finite element analysis and machine learning can provide valuable insights into the behavior of these structures. A series of experiments have been designed and analyzed for hybrid composite tubes used in robotic arm applications, particularly focusing on fiber-reinforced polymer (FRP) materials wrapped around aluminum tubes. Filament winding is a well-known technique for applying FRP to tubes, and the primary approach in this investigation was analyzed using ANSYS Composite Pre/Postprocessor (ACP). The study investigates three models of hybrid composite pipes, varying the number of layers and the winding angle. Each model was subjected to cantilever loading at various node points, while keeping the wall thickness of the tube constant at 3 mm. The model with a CFRP winding angle of 45° and a layer thickness of 1.5 produced the best results compared to the others. It was observed that both the bending moment and shear stress of the tube increased with a rising winding angle, whereas the strain energy of the tube decreased with an increasing winding angle. The optimal winding angle was determined to be 45°. Additionally, the stresses on the filament-wound tubes under different load conditions were optimized, and a statistical analysis was conducted using Mini-Tab. The research further focused on identifying the maximum failure loading conditions for optimal parameters through composite failure analysis. The failure conditions of the composite tube under maximum sustainable parameters were compared with those of standard aluminum and CFRP tubes. The hybrid tube demonstrated less deformation and stress compared to the other models.
{"title":"Structural analysis of hybrid composite arms for light weight robots","authors":"Manchi Nageswara Rao , Arockia Selvakumar Arockia Doss , Daniel Schilberg","doi":"10.1016/j.engfailanal.2025.109520","DOIUrl":"10.1016/j.engfailanal.2025.109520","url":null,"abstract":"<div><div>Robot structures made of steel or aluminum tend to be heavy and can undergo significant deformation, which leads to increased power consumption and a higher risk of failure under load conditions. Therefore, it is essential to create lighter-weight structures without compromising the performance of the robot. Taguchi methods can be employed to design these lightweight robot structures and optimize their performance. Additionally, finite element analysis and machine learning can provide valuable insights into the behavior of these structures. A series of experiments have been designed and analyzed for hybrid composite tubes used in robotic arm applications, particularly focusing on fiber-reinforced polymer (FRP) materials wrapped around aluminum tubes. Filament winding is a well-known technique for applying FRP to tubes, and the primary approach in this investigation was analyzed using ANSYS Composite Pre/Postprocessor (ACP). The study investigates three models of hybrid composite pipes, varying the number of layers and the winding angle. Each model was subjected to cantilever loading at various node points, while keeping the wall thickness of the tube constant at 3 mm. The model with a CFRP winding angle of 45° and a layer thickness of 1.5 produced the best results compared to the others. It was observed that both the bending moment and shear stress of the tube increased with a rising winding angle, whereas the strain energy of the tube decreased with an increasing winding angle. The optimal winding angle was determined to be 45°. Additionally, the stresses on the filament-wound tubes under different load conditions were optimized, and a statistical analysis was conducted using Mini-Tab. The research further focused on identifying the maximum failure loading conditions for optimal parameters through composite failure analysis. The failure conditions of the composite tube under maximum sustainable parameters were compared with those of standard aluminum and CFRP tubes. The hybrid tube demonstrated less deformation and stress compared to the other models.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109520"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143631871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wheel polygonization (polygonal wear) changes the wheel–rail contact and the wheel–brake shoe contact, which in turn changes the wheel temperature and the resulting rolling contact fatigue during tread braking. A simulation procedure based on the transient fully coupled thermomechanical finite element method is developed to investigate the response of the wheel material in the elastoplastic region, taking into account the synergistic effect of non-uniform thermal load and cyclic mechanical load due to wheel polygonization. The Dowling damage formula, Jiang–Sehitoglu fatigue model and Kapoor model are applied to investigate the rolling contact fatigue from the aspects of high cycle fatigue, low cycle fatigue and ratcheting failure, respectively. The temperature, stress–strain response, and fatigue pattern of a polygonised and a non-polygonised wheel during tread braking are compared. The simulation results show that wheel polygonization results in localized areas of low temperature at the troughs, while significantly higher temperature bands occur at the edges of contact hollows. Radial and circumferential compressive stresses and surface material flow increase as some stress–strain components tend to shakedown. Fatigue damage worsens especially at the polygonization crest, where the critical plane of crack initiation is more oblique to the axial direction and more towards the tread surface, while the ratcheting failure is attenuated. This research draws particular attention to polygonised wheels against excessive local temperature and rolling contact fatigue.
{"title":"Numerical study on temperature and thermomechanical rolling contact fatigue of polygonised wheel during tread braking","authors":"Yifei Luo, Changwen Tan, Zhijun Zhou, Gongquan Tao, Zefeng Wen, Wenjian Wang","doi":"10.1016/j.engfailanal.2025.109526","DOIUrl":"10.1016/j.engfailanal.2025.109526","url":null,"abstract":"<div><div>Wheel polygonization (polygonal wear) changes the wheel–rail contact and the wheel–brake shoe contact, which in turn changes the wheel temperature and the resulting rolling contact fatigue during tread braking. A simulation procedure based on the transient fully coupled thermomechanical finite element method is developed to investigate the response of the wheel material in the elastoplastic region, taking into account the synergistic effect of non-uniform thermal load and cyclic mechanical load due to wheel polygonization. The Dowling damage formula, Jiang–Sehitoglu fatigue model and Kapoor model are applied to investigate the rolling contact fatigue from the aspects of high cycle fatigue, low cycle fatigue and ratcheting failure, respectively. The temperature, stress–strain response, and fatigue pattern of a polygonised and a non-polygonised wheel during tread braking are compared. The simulation results show that wheel polygonization results in localized areas of low temperature at the troughs, while significantly higher temperature bands occur at the edges of contact hollows. Radial and circumferential compressive stresses and surface material flow increase as some stress–strain components tend to shakedown. Fatigue damage worsens especially at the polygonization crest, where the critical plane of crack initiation is more oblique to the axial direction and more towards the tread surface, while the ratcheting failure is attenuated. This research draws particular attention to polygonised wheels against excessive local temperature and rolling contact fatigue.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"174 ","pages":"Article 109526"},"PeriodicalIF":4.4,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143628562","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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