Local Damage Research Articles

Modeling local deformation, damage distribution, and phase transformation in zirconia particle-reinforced TRIP steel composites

This study investigates tensile deformation, damage analysis, and the effect of microtexture on a 10 % vol. zirconia particle-reinforced TRIP steel composite. In situ tensile tests and simulations were conducted, with sequential SEM images captured during tensile loading tests and electron backscatter diffraction (EBSD) providing initial crystal orientation data. SEM images were utilized in digital image correlation (DIC) analysis to calculate the local plastic strain distribution using VEDDAC software. Initial micrographs and EBSD data were transformed into geometry files for simulations, employing crystal plasticity with a dislocation density-based model and a newly proposed phase field approach-based ductile-brittle damage criterion for both austenite and ceramic particles. MATLAB's image processing functions were used to compare and validate experimentally observed damage instances with simulation predictions. The effect of microtexture combined with various physical quantities was explored using MTEX. The results show that the simulations accurately predict strain concentration around ceramic particles, with a higher strain observed in the middle region compared to the DIC observations. The simulated strain in the austenitic matrix is found to be 1.4 times higher than the DIC measurements. Quantitative analysis of damage pixels reveals that the proposed critical plastic strain value aligns closely with experimental results, showing an error of - 0.25 % compared to 1.121 % for a smaller strain case. This comprehensive analysis provides insight into the effect of microstructural attributes on material performance and behavior under tensile deformation, leading to a validated microstructural-informed damage-inclusive crystal plasticity model.

Enhanced strength, toughness and reliability in crab exoskeleton–inspired 3D-printed porous thermoplastics

PurposeFused deposition modeling enables multiscale structure control. However, most of this structural space is unexplored. Specifically, the impact of biomimetic porous structures on the mechanical behavior and reliability of common thermoplastics are unclear. In this work, porous structures inspired by the multifunctional crab exoskeleton were 3D-printed with different raster orientations, including fully rotating rasters similar to Bouligand structures found in biological materials. Tensile tests and simulations were performed to observe the stochastic behavior of fracture properties and to reveal the underlying origins of mechanical reliability in biomimetic porous systems.Design/methodology/approachTensile tests were performed on 3D-printed porous structures with four different rasters. These rasters were biomimetic Bouligand, semi-Bouligand, 00 raster and 45°/−45° raster. In addition, two different sets were manufactured to observe the impact of contours on the mechanical behavior. A total of 137 tensile tests were performed. A total of 88 finite element simulations were executed using Abaqus built-in Hashin damage initiation criterion and energy-based damage evolution law. Weibull analyses were performed to quantify the stochastic properties.FindingsBiomimetic Bouligand structure is effective in increasing fracture strength. Average fracture strength of the Bouligand structure was 33% higher compared to the default 45°/−45° and 10% higher compared to 00 rasters. Variations in strength were lower in Bouligand structure compared to the default 45°/−45° raster. However, 00 raster had the highest Weibull modulus m = 54 compared to Bouligand m = 25 and 45°/−45° m = 17. Simulations showed that Bouligand structure is effective in increasing the mechanical reliability through local damage accumulation around the holes. The simulated Weibull modulus of the Bouligand structure was 40 compared to the moduli of other rasters that ranged from 18 to 25.Practical implicationsThe mechanical reliability of porous Bouligand structures is higher compared to other rasters, which makes the biomimetic structure a better choice for industrial applications. Contours decrease the strength and strain at failure for 3D-printed porous structures. Bouligand structures with rotating raster orientations increased strength and strain at failure when contours are present in the porous structure.Originality/valueTo the best of the authors’ knowledge, this is the first study showing the effects of biomimetic raster orientations on the mechanical behavior and the effects of contours on the tensile fracture properties of 3D-printed porous acrylonitrile butadiene styrene using tensile tests and fracture simulations. This is the first study applying composite fracture model to anisotropic porous 3D-printed polymers.

Estimating bridge stress histories at remote locations from vibration sparse monitoring

Structural health monitoring with accelerometers provides notable benefits over strain gauges, particularly in installation time and cost efficiency. However, effective local damage assessment necessitates access to local stress histories. This paper proposes a methodology that integrates two distinct approaches to identify and predict stress and strain across various bridge locations from sparse monitoring via acceleration data. The proposed model is validated using strain histories and accelerations collected from the composite railway Bryngeån Bridge in Sweden during its in-service conditions. Initially, a deep learning algorithm for sequence data is employed to forecast strain histories from acceleration data gathered across various bridge locations. Subsequently, the local response function method is implemented, utilizing experimental data collected from the bridge and employing localized models of its substructures, allowing predictions of the bridge’s local strain. By integrating these methods, the approach enables accurate prediction of stress ranges and cycles for critical non-instrumented parts, minimizing the need for extensive direct instrumentation and providing a cost-effective, efficient solution for operational structural health monitoring.

An effective vibration-based feature extraction method for single and multiple damage localization in thin-walled plates using one-dimensional wavelet transform: A numerical and experimental study

By early detection of single and multiple damaged locations and repairing or replacing defective elements, it is possible to prevent damage to other areas and structural elements. The use of thin-walled steel plates is on the rise in the building industry. Damage to these elements can progressively develop and spread to other elements, resulting in overall structural damage. This article focused on detecting single and multiple damaged locations in thin-walled steel plates. An effective feature extraction method based on wavelet analysis with a one-dimensional theoretical background to analyze two-dimensional modal signals was introduced. This method calculates the peak of disturbances and irregularities in various damaged locations and their surrounding areas. The suggested method was used to identify the center of single and multiple damaged areas with an error of less than 5 %. The numerical and experimental results confirmed the effectiveness and efficiency of the proposed method in detecting various damaged locations.

Mechanical–thermal coupling in micro-nanocavity graphene/paraffin phase change energy storage materials for heat management

Combining the superior thermal conductivity of graphene and the outstanding heat storage of paraffin, micro-nanocavity graphene/paraffin nanocomposites (MNGPNs) have recently served as promising thermal management materials in high-power microelectronic devices. However, current evaluations of the thermal management performances of MNGPNs are restricted in the lab condition, deviating from the complex mechanical–thermal coupling environment in practical scenarios. Here, we have investigated the structural and thermal management properties of MNGPNs with varying mechanical loads by in situ electron microscopy and in situ thermal characterizations. Our results reveal distinct mechanical–thermal coupling effects along in-plane and out-of-plane directions of MNGPNs. Specifically, mechanical loading reduces the porosity and enhances the heat transfer capacity of MNGPNs in the out-of-plane direction, while mechanical loading along the in-plane direction causes local damage to the graphene structure and weakens the heat transfer capacity of MNGPNs. Since the heat management performance of MNGPNs is dominated by the in-plane thermal transport, MNGPNs with mechanical loading show a delayed phase transition response time and unchanged phase transition enthalpy. This work provides in situ mechanical guidance for the practical application of MNGPNs for heat management.

An efficient multi-scale method for failure mechanism analysis of SiCf/Ti composites with experimental validation

This study focuses on developing and validating a high-precision concurrent multi-scale finite element model considering the progressive damage model (PDM) and the cohesive zone model (CZM) for predicting the damage evolution of SiCf/Ti composites. At the macro-scale, a constitutive model describing the anisotropic damage criterion of SiCf/Ti composites was implemented by means of a user-defined subroutine (VUMAT). Meanwhile, based on the submodelling, a representative volume element (RVE) model was developed to systematically analyze the failure modes of the SiC fibers, the matrix, and the interface, respectively. Specifically, the crack initiation and propagation in the stress concentration zones were further discussed. Simultaneously, experimental methods were employed to verify the feasibility of the current model. During the uniaxial compression, the brittle fracture of the SiC fibers and ductile fracture of the matrix are the predominant failure modes of SiCf/Ti composites, with fiber fracture being the dominant factor. The crack initiates at the fibers, propagates rapidly to the fiber-matrix interface, and then extends into the matrix. Moreover, the fracture locations are suscepticle to stress concentrations, leading to the crack initiation and propagation. The predicted results show that the local damage has a significant effect on the failure mechanism of SiCf/Ti composites and this multi-scale model provides a scientific reference for the design and optimization of composites.

Bolt looseness localization with connection-stiffness-varying flange

Electromechanical impedance analysis is a traditional method to identify the occurrence of bolt looseness, but accurate localization of blot looseness is hard to realize on the flange. In this study, a flange model with bolt connection stiffness varying with position is proposed. The location of bolt looseness can be then determined from the impedance spectrum of the model since the uniformity and symmetry of the flange are broken. The analytic model is established to reveal the distinguishability of the eigenfrequency shifting characteristics when the connection stiffness at different positions changes. The frequency shifting sequence is extracted from the coupling impedance spectrum as a feature, and the correlation between the sequences corresponding to bolt looseness at different positions is low. The relationship between the sequence and the degree of looseness is highly related so that the unknown degree of looseness can be matched with the calibrated sequence to realize the localization of the looseness. Based on the distinguishability of the frequency shifting sequence, the connection-stiffness-varying model shows great potential in the field of flanges or other connecting structures for structural health monitoring and damage localization.

Shaking table test on progressive collapse of the double-layer cylindrical reticulated shell with infilled wall

Double-layer cylindrical reticulated shell has made rapid development in recent decades in China, which is widely used in the large-scale public buildings such as gymnasiums, airplane terminal, Shopping mall, etc. Stability and progressive collapse mechanism have been attracting a lot of attention because the large span space structure is largely affected by the geometry nonlinear, which makes it sensitive to the local damages. The infilled wall has a greater impact on the stiffness of the lower supporting structure due to sparse column grid. However, the influence of infilled walls on the collapse mechanism of large-span spatial structures is very complex due to the coupling of upper and lower structures. Therefore, the effects of infilled walls on double-layer cylindrical reticulated shell was investigated by a series of progressive collapse tests with shaking table. In order to evaluate the seismic performance and the capacity of resisting progressive collapse, the structural dynamic characteristics and response laws were obtained under different ground motions and input principal directions. The results indicated that the existence of infilled wall made the coupling between the lower supporting structure and the upper roof structure more complicated. The infilled walls influenced the structural damage evolution and development, mitigated the damage from the earthquake and changed the progressive collapse pattern, which made the catenary collapse mechanism occur when the structure collapsed. Although the further quantitative study is still needed, this paper provides lots of useful test data and conclusions, which gives references to the infilled wall design and seismic performance evaluation for double-layer cylindrical reticulated shell.

Changes in protein fluxes and gene expression in non-injured muscle tissue distant from an acute myotoxic injury in male mice.

The response to acute myotoxic injury requires stimulation of local repair mechanisms in the damaged tissue. However, satellite cells in muscle distant from acute injury have been reported to enter a functional state between quiescence and active proliferation. Here, we asked whether protein flux rates are altered in muscle distant from acute local myotoxic injury and how they compare to changes in gene expression from the same tissue. Broad and significant alterations in protein turnover were observed across the proteome in the limb contralateral to injury during the first 10days after. Interestingly, mRNA changes had almost no correlation with directly measured protein turnover rates. In summary, we show consistent and striking changes in protein flux rates in muscle tissue contralateral to myotoxic injury, with no correlation between changes in mRNA levels and protein synthesis rates. This work motivates further investigation of the mechanisms, including potential neurological factors, responsible for this distant effect. KEY POINTS: Previous literature demonstrates that stem cells of uninjured muscle respond to local necrotic muscle tissue damage and regeneration. We show that muscle tissue that was distant from a model of local necrotic damage had functional changes at both the gene expression and the protein turnover level. However, these changes in distant tissue were more pronounced during the earlier stages of tissue regeneration and did not correlate well with each other. The results suggest communication between directly injured tissue and non-affected tissues that are distant from injury, which warrants further investigation into the potential of this mechanism as a proactive measure for tissue regeneration from damage.

Breaking the chain in organ failure: Role of umbilical cord and bone marrow derived mesenchymal stem cells in treatment of severe acute pancreatitis

BackgroundPrevious studies showed that MSCs could mitigate damage in the pancreas during acute pancreatitis (AP). However, acute mortality associated with AP was more often a result of persistent failure of remote organs, rather than local damage, especially in severe acute pancreatitis (SAP), and the effect of MSCs may vary depending on their origin. MethodsAn SAP model was induced in 8-week C57BL/6 J male mice by retrograde injection of 5 % sodium taurocholate solution through the bile duct. SAP mice were divided into the SAP group, UC-MSCs group, and BMSCs group, which were treated with saline, 1 × 106 UC-MSCs, and 1 × 106 BMSCs respectively, through the tail vein. After treatment, serum markers, inflammation, and morphology were assessed in the pancreas, kidneys, lungs, and hearts. ResultsMSCs infusion ameliorated the systemic inflammatory response in SAP mice. In the MSCs-treated SAP mice, local tissue injury and inflammation response in the pancreas were alleviated. But more importantly, the renal and lung injury were all significantly and drastically mitigated, and the levels of pro-inflammatory factors such as IL-6, MCP-1, IL-1β, and TNF-α in the kidney, lung and heart were sharply decreased. In terms of origin, UC-MSCs exhibited superior efficacy compared with BMSCs. Furthermore, compared to the normal control mice, UC-MSCs showed an earlier appearance, higher distribution densities, and longer duration of presence in the injured tissue. ConclusionsThis study provides compelling evidence supporting the therapeutic potential of MSCs in SAP treatment and particularly their ability to mitigate multi-organ failure. Our results also suggested that UC-MSCs may offer greater advantages over BMSCs in SAP therapy.

Damage identification of simply-supported beams based on SD value method

Abstract Combining the relationships among the displacement mode, rotation mode, and curvature mode, this study proposes a structural curvature variance ratio (SD) method that can simplify the calculation and reduce the damage recognition error. Using beam structures in the western region as an example, a finite element model is established, and the impact of the displacement modulus on beam damage recognition is analyzed. The applicability of the SD method for damage recognition is also investigated. In the presence of measurement errors, the SD method and the curvature modulus difference method are compared and analyzed. The results show that this method can effectively identify structural damage, determine the location and quantity of local damage, and simplify calculations while reducing error transmission and amplification.

Whole-body exposure to filtered fraction of diesel exhaust induced localized testicular damage through attenuated functional response of glutathione-s-transferase in adult male Wistar rats

The possible vulnerability of the male reproductive system to environmental pollutants such as air pollution necessitates a thorough investigation of the underlying mechanisms involved in the dysregulation of male reproductive function. The present study was designed to investigate the influence of the filtered fraction of diesel exhaust (predominantly comprising gases) on male reproductive function in Wistar rat model. Adult male rats were randomly assigned into three groups (n=8/group): Control (unexposed) group (CG-A), the Clean air group in WBE chamber (CAG-A), and Filtered diesel exhaust group in WBE chamber (FDG-A). The exposure protocol for CAG-A and FDG-A was 6 h/day x 5d/week x 6 weeks,evaluation of sperm parameters, testicular histopathology, quantification of hormones (testosterone, LH, FSH, 17β-Estradiol, and prolactin), and GST levels were performed. Results showed that WBE to FDE leads to a significant decline in sperm concentration (p=0.008, CG-A vs FDG-A; p=0.014, CAG-A vs FDG-A), motility (p=0.008, CG-A vs FDG-A; p=0.029, CAG-A vs FDG-A), serum testosterone (p=0.024, CG-A vs FDG-A; p=0.007, CAG-A vs FDG-A), testicular testosterone (p=0.008, CG-A vs FDG-A; p=0.028, CAG-A vs FDG-A), 17β-Estradiol (p=0.007, CG-A vs FDG-A), and GST levels (p=0.0002, CG-A vs FDG-A; p=0.0019, CAG-A vs FDG-A). These findings demonstrate the disruption of testosterone-estradiol balance in the intratesticular milieu without significant alterations in other principal pituitary hormones in adult rats exposed to FDE. The predominant presence of gaseous components in FDE can cause testicular damage due to oxidative imbalance. This underscores the causality of FDE exposure and impaired male reproductive outcomes.

Phased array-based nonlinear wave mixing technique: Application to lack-of-fusion porosity characterization in additively manufactured metals.

The objective of this research is to demonstrate the effectiveness of a phased array-based nonlinear wave mixing technique to characterize internal, localized microscale damage in an additively manufactured (AM) component. By using phased arrays for the generation of the incident waves, it is possible to produce a nonlinear wave mixing scanning technique without the need for immersion or changing coupling conditions. The phased arrays can be configured to generate incident waves in multiple directions that meet the resonance conditions required for nonlinear wave mixing at a variety of internal locations. This allows for the scanning of a specimen without the removal and re-coupling of the source transducers, leading to greater scanning speed and repeatability. To demonstrate the accuracy of this phased array wave mixing approach, measurements of acoustic nonlinearity in an AM component are first made with a bulk wave second harmonic generation through thickness measurement. Next, nonlinear wave mixing measurements are made with single element transducers to confirm the sensitivity of the proposed nonlinear wave mixing approach to lack-of-fusion porosity in AM metals. Finally, phased arrays are used to highlight the effectiveness of the proposed nonlinear wave mixing technique in these same AM components.

Integrated multi-omics analysis reveals molecular changes associated with chronic lipid accumulation following contusive spinal cord injury

Functional and pathological recovery after spinal cord injury (SCI) is often incomplete due to the limited regenerative capacity of the central nervous system (CNS), which is further impaired by several mechanisms that sustain tissue damage. Among these, the chronic activation of immune cells can cause a persistent state of local CNS inflammation and damage. However, the mechanisms that sustain this persistent maladaptive immune response in SCI have not been fully clarified yet.In this study, we integrated histological analyses with proteomic, lipidomic, transcriptomic, and epitranscriptomic approaches to study the pathological and molecular alterations that develop in a mouse model of cervical spinal cord hemicontusion.We found significant pathological alterations of the lesion rim with myelin damage and axonal loss that persisted throughout the late chronic phase of SCI. This was coupled by a progressive lipid accumulation in myeloid cells, including resident microglia and infiltrating monocyte-derived macrophages. At tissue level, we found significant changes of proteins indicative of glycolytic, tricarboxylic acid cycle (TCA), and fatty acid metabolic pathways with an accumulation of triacylglycerides with C16:0 fatty acyl chains in chronic SCI. Following transcriptomic, proteomic, and epitranscriptomic studies identified an increase of cholesterol and m6A methylation in lipid-droplet-accumulating myeloid cells as a core feature of chronic SCI.By characterizing the multiple metabolic pathways altered in SCI, our work highlights a key role of lipid metabolism in the chronic response of the immune and central nervous system to damage.

Progress and Challenges of Topical Delivery Technologies Meditated Drug Therapy for Osteoarthritis.

Osteoarthritis (OA) is a degenerative disease commonly seen in middle-aged and elderly people. Multiple cytokines are involved in the local tissue damage in OA. Currently, non-pharmacologic and surgical interventions are the main conventional approaches for the treatment of OA. In terms of pharmaceutical drug therapy, NSAIDs and acetaminophen are mainly used to treat OA. However, it is prone to various adverse reactions such as digestive tract ulcer, thromboembolism, prosthesis loosening, nerve injury and so on. With the in-depth study of OA, more and more novel topical drug delivery strategies and vehicles have been developed, which can make up for the shortcomings of traditional dosage forms, improve the bioavailability of drugs, and significantly reduce drug side effects. This review summarizes the immunopathogenesis, treatment guidelines, and progress and challenges of topical delivery technologies of OA, with some perspectives on the future pharmacological treatment of OA proposed.

Temperature Effect on the Properties and Response of Composite Materials and Plates

The paper illustrates the effect of temperature on composite material properties and its influence on the response of composite plates. Two composites considered include laminae with uniaxially oriented and with in-plane randomly oriented fibers. Analytical solutions are presented for a uniformly heated large-aspect-ratio plate deforming into a cylindrical surface. The solutions are demonstrated for thermal buckling and natural frequencies for the cases of controlled loading and controlled displacements. Micromechanical residual and lifetime thermally induced stresses at the interface of fibers and matrix are assessed to predict a possible onset of local damage after the curing and during lifetime. The material considered in numerical examples consists of silicon carbide fibers and a titanium alloy matrix. The moduli of elasticity and shear as well as the coefficients of thermal expansion of this composite are significantly affected by temperature. The thermally induced microscopic radial stress at the fiber–matrix interface is high, so it should be monitored in silicon fiber titanium matrix composites to avoid the onset of local damage. In conclusion, accounting for the effect of temperature on material properties is highly desirable since it produces more accurate solution than those utilizing the properties at the room temperature.

NIR-Absorbing Tetraphenylethene-Containing bisBODIPY Nanoplatforms Demonstrate Effective Lysosome-Targeting and Combinational Phototherapy.

Photosensitizer-based phototherapies, including photodynamic therapy (PDT) and photothermal therapy (PTT), offer safe treatment modalities for tumor ablation with spatiotemporal precision. After photons are absorbed, PDT creates localized chemical damage by generating reactive oxygen species (ROS), while PTT induces localized thermal damage. However, PDT still faces hypoxic tumor challenges, while PTT encounters issues related to heat resistance and potential overheating. The combination of PDT and PTT shows great potential as an effective anticancer strategy. By targeting lysosomes with carefully designed phototherapeutic reagents for combined phototherapy, rapid dysfunction and cell death in cancer cells can be induced, showing promise for cancer treatment. Herein, two α-α-linked bisBODIPYs with tetraphenylethene (TPE) moieties are designed and synthesized. These TPE-substituted bisBODIPYs expand the absorption into NIR range (λmaxabs/λmaxem ∼ 740/810 nm) and confer aggregation-induced emission (AIE) activity (λmaxem ∼ 912 nm). Moreover, these bisBODIPYs self-assemble with surfactant F-127 into nanoparticles (NPs), which efficiently generate ROS (1O2 and •OH) in both solution and cellular environments and demonstrate superior photothermal conversion efficiencies (η ∼ 68.3%) along with exceptional photothermal stability. More importantly, these NPs showed lysosomal targeting and remarkable tumor ablation in cellular and murine models, indicating their potential in precision tumor therapy.

Eigenfrequency analysis using fiber optic sensors and low-cost accelerometers for structural damage detection

Structural Health Monitoring (SHM) is crucial for infrastructure safety and integrity. Arduino-based sensors are gaining popularity in low-cost SHM structures. Distributed fiber optic systems (DFOS), such as Distributed Acoustic Sensing (DAS), are employed for accurate SHM despite their high costs, computational demands, and energy consumption. The primary objectives of this work are to compare the accuracy of an accelerometer named LARA (Low-cost Adaptable Reliable Accelerometer (LARA)) that utilizes both Arduino and Raspberry Pi technologies with a DAS system in detecting structural damage and to explore the potential advantages of combining LARA and DAS to create an effective SHM tool. This study is the first to enhance the design of LARA. Subsequently, LARA and DAS were used in a laboratory setting to analyze eigenfrequency changes in a beam model with induced localized damage. Finally, this study evaluated the precision and reliability of LARA and its potential role as a trigger for DAS in detecting localized damage. The findings show that both LARA and DAS can identify changes in the eigenfrequencies of damaged structures with deviations as small as 3.68 %. Consequently, LARA demonstrated its potential as a trigger for DAS, significantly reducing the computational demands while enriching the analysis. This approach offers highly accurate eigenfrequency measurements and enhances the analytical capabilities of DAS by identifying the primary axes of the detected eigenfrequencies.

Structural damage identification by using physics-guided residual neural networks

In recent years, vibration-based structural damage identification has made significant progress by exploiting data-driven deep learning techniques, which can efficiently extract damage-sensitive features from a large amount of data. However, in some practical engineering applications, large volumes of measurement data are not readily available. This paper proposes a novel physics-guided residual neural network (PhyResNet) framework to improve the robustness and accuracy of structural damage identification under data-scarce conditions. In contrast to the state-of-the-art purely data-driven ResNet, the proposed method embedded available physics knowledge (e.g., governing equations of dynamics) of structures into the feature learning process via a novel physics-based loss function. The input-output relationship of the network is constrained to retain its physical meaning implicitly while the demand for large amounts of labeled training data is reduced. Notably, even with only 5 % of the dataset used for training, PhyResNet achieves a 13.1 % improvement in R-Value. The performance of the proposed approach is evaluated through both numerical and experimental verifications. Results demonstrate that damage localization and quantification are achieved with high accuracies and good robustness.

Prediction of cutting forces, damage locations and machined surface integrity in machining of circular-cell honeycomb composites: Simulations, parametric effects and experimental validations

The machining of honeycomb cores presents challenges due to exerted unbalanced cutting forces from discontinuous hexagonal structures, where severe tool wear and cracking on the machined surface occurs. In this study, the established cutting force models consider alterations of the wall thickness and immersion angles when mono-oblique and duplex-oblique cutting tools are engaged. The maximum cutting forces and the produced damages compared to the tool positions are analytically simulated and validated. The increased cutting temperatures and the shear stress gradients with respect to cutting speeds and feed rates were analysed after fitting them with the experimental results. Moreover, the vibration-induced cutting-edge-rounding and fracturing on the machined surface were identified. In the validation experiments, a wide range of cutting speeds (100–300 m/min) and feed rates (0.2–1.0 mm/rev) were operated for practical utilities. It was proven that the highest cutting forces (∼26.59 N) took place at the entry node of the hexagonal cell; whilst the cutting forces’ fluctuations (±20.35 N) under high frequency (∼2.5 kHz) and high intensity (∼ 8290 dB) could result in cutting-edge rounding from tool wear. The damage locations on the machined surfaces, as well as the corresponding fracturing mechanisms of fibres incubating the in-plane and out-of-plane cracks were verified and discussed.