High Normal Stress Research Articles

Experimental and Numerical Study on Nonlinear Shear Behavior and Constitutive Model of Deep Shale Laminae Planes

The direct shear tests showed that the degradation of unevenness and waviness of the laminae plane is the primary reason for the dynamic decrease in shear strength. A shear constitutive model was proposed which considers the scale effect and the asperity geometry of the unevenness and waviness of the laminar plane. The evolution of the shear strength and stiffness with a normal stress and scale effect during the shearing of shale laminae planes was explored. The results show that high normal stress aggravates the stiffness hardening of laminae planes and forms larger peak shear stress and peak shear displacement. At the lab scale, the increase in the unevenness wavelength has a hardening effect on the shear stiffness and strength. The small-scale unevenness contributes most to the shear strength of shale laminae planes at the lab scale. At the field scale, the increase in the waviness wavelength has a softening effect on the shear stiffness and strength.

Mechanical behavior of en-echelon joints under cyclic shear loading conditions: Roles of joint persistence and loading conditions

Studying the mechanical response of en-echelon joints under cyclic shear loading conditions can provide novel insights into the instability of jointed rock masses under seismic conditions. To investigate the effects of joint persistence, normal stress, cyclic distance, and shear velocity on the cyclic shear behavior of en-echelon joints, a series of cyclic shear tests in the laboratory was performed. Findings revealed that the failure morphography of en-echelon joints manifested through brecciated shear zones and abraded rupture surfaces, resulting in notable reductions in shear strength and significant compressibility. The degradation factor of shear strength ranged from 0.363 to 0.708 after ten cycles. The shear strength degradation factor showed an inverse relationship with joint persistence and normal stress while exhibiting a direct correlation with cyclic distance over ten cycles. En-echelon joints characterized by moderate joint persistence, high normal stress, small cyclic distance, and low shear velocity demonstrated increased cyclic friction strength. Moreover, normal stress and joint persistence exerted a more significant influence on shear strength compared to cyclic distance and shear velocity. For en-echelon joints, shear stiffness increased during small shear displacements with cycle number while decreased during large shear displacements; shear stiffness was inversely proportional to the cyclic distance and joint persistence, and directly proportional to the normal stress. Compressibility of en-echelon joints correlated directly with joint persistence, normal stress, cyclic distance, and shear velocity. Compared to normal stress and cyclic distance, joint persistence and shear velocity exhibited less influence on compressibility

Evolution of mechanical behavior in granular soil during fine particle loss simulated by salt dissolution: Insights from ring shear tests

Fine particle loss in soil is one of the main causes of slope instability and geotechnical structure failure. Loss of fines can cause instability in granular assembles by changing the fabric and microstructure of the sample. However, real-time monitoring of the evolution of mechanical behavior in granular soils during the particle loss process is still poorly explored. This study presents a novel approach by simulating fine particle loss through salt dissolution in ring-shear tests, offering real-time insights into the mechanical evolution of granular soils under realistic stress conditions. Meanwhile, the shear resistance, shear displacement, vertical displacement, salt content, and acoustic emissions were simultaneously recorded. The test results showed that the instability of the sample was triggered by the loss of fine particles. With a gradual loss of fine particles, both the vertical and shear deformations and the void ratio increased. The evolution of shear resistance in the sample can be divided into three stages: stress weakening, then strengthening, and finally recovery to the initial value. We infer that the evolution of shear resistance originated from the collapse and rearrangement of its granular fabric and microstructure. Additional evidence for this hypothesis was provided by high-frequency acoustic emissions (approximately 150 kHz), suggesting buckling of the force chains accompanying the particle loss process. Furthermore, the sample experienced greater shear deformations and stress weakening that developed under a larger initial fine content or a higher normal stress. This finding may provide valuable insights into the mechanical behavior of granular soil during the fine particle loss process.

Evolution of Power‐Law Particle‐Size Distributions in Dense Grain‐Flow Experiments

AbstractUnderstanding particle fragmentation and its resulting particle‐size distribution is essential for comprehending shear zone formation, structure, and frictional behavior in faults and landslides, particularly at high normal stresses. 3‐D fractal dimension (D3) is used as a measure of particle‐size distribution, and for the potential self‐similarity physics. Previous research suggests D3 – 2.58 based on the “constrained comminution” model, or D3 = 3.00 considering large shear displacement. However, field data from rock avalanches reveal scattered D3 that deviate from these predictions, possibly due to the neglection of the underlying fragmented physics, such as the particle‐size‐dependent fragmentation probability. Herein, we conducted rotary shear experiments to investigate the evolution of D3 under varying normal stresses, velocities, and mineral compositions. Experimental results demonstrate that D3 monotonically increases with shear displacement and converges to an ultimate value, significantly influenced by mineral composition but less affected by shear velocity and confining stress within the experimental conditions. A modified large‐strain model that considered size‐dependent grain‐breakage probability was proposed, which may explain the observed divergence of D3 from previous predictions. This model highlights the complex mechanisms involved in particle breakage within dense grain‐flows, resulting in the high but scattered D3 observed in natural shear zones. Furthermore, we recognize that additional mechanisms, such as abrasion and grinding, can contribute to the particle size reduction and influence the ultimate fractal dimension. This study provides valuable insights into the dynamics of particle fragmentation in shear zones and has implications for understanding various geological processes.

Unstable Sliding of Plagioclase Gouge and Deformation Mechanisms Under Hydrothermal Conditions With Effective Normal Stresses of 100–300 MPa

AbstractPlagioclase feldspar is a major mineral in mafic crustal rocks. To better understand the deformation mechanism of plagioclase feldspar during frictional faulting, we conducted shearing experiments on simulated plagioclase gouge in a wide range of effective normal stress of 100–300 MPa, pore‐water pressure of 30–100 MPa, and temperatures ranging from 100°C to 600°C. The coefficient of friction is found to range from 0.65 to 0.74 across the entire temperature range, showing no significant thermal weakening process. Except for a case at 200°C with an effective normal stress of 300 MPa, the frictional sliding is velocity weakening over the whole temperature range, showing a steady‐state rate dependence (a−b) ranging from −0.5 × 10−3 to −8.6 × 10−3. This property facilitates nucleation of unstable slips in frictional faulting. Above 200°C, the direct rate effect parameter (a) and the evolution effect parameter (b) of friction increase with temperature up to a threshold of 400°C or 500°C, depending on the effective normal stress. This thermal enhancement suggests thermally activated creep at contact junctions governed by intergranular pressure solution, as evidenced by microstructural signatures indicating the prevalence of very fine precipitates formed at the surfaces of gouge particles as a result of pressure solution. In frictional sliding of plagioclase, a low effective normal stress of 100 MPa corresponds to a higher degree of velocity weakening and tends to facilitate seismic slip rather than slow slips, whereas the high effective normal stress of 300 MPa corresponds to a minor velocity weakening which may cause slow‐slip events in faults of limited size.

Effects of joint persistence and testing conditions on cyclic shear behavior of en-echelon joints under CNS conditions

Cyclic shear tests on rock joints serve as a practical strategy for understanding the shear behavior of jointed rock masses under seismic conditions. We explored the cyclic shear behavior of en-echelon and how joint persistence and test conditions (initial normal stress, normal stiffness, shear velocity, and cyclic distance) influence it through cyclic shear tests under CNS conditions. The results revealed a through-going shear zone induced by cyclic loads, characterized by abrasive rupture surfaces and brecciated material. Key findings included that increased joint persistence enlarged and smoothened the shear zone, while increased initial normal stress and cyclic distance, and decreased normal stiffness and shear velocity, diminished and roughened the brecciated material. Shear strength decreased across shear cycles, with the most significant reduction in the initial shear cycle. After ten cycles, the shear strength damage factor D varied from 0.785 to 0.909. Shear strength degradation was particularly sensitive to normal stiffness and cyclic distance. Low joint persistence, high initial normal stress, high normal stiffness, slow shear velocity, and large cyclic distance were the most destabilizing combinations. Cyclic loads significantly compressed en-echelon joints, with compressibility highly dependent on normal stress and stiffness. The frictional coefficient initially declined and then increased under a rising cycle number. This work provides crucial insights for understanding and predicting the mechanical response of en-echelon joints under seismic conditions.

Modelling transport pathways of faults with low hydraulic connectivity in mudstones with low swelling capacity

Faults in some deep mudstones have poor hydraulic connectivity owing to high normal stress on the fault planes. Designing a method for modelling solute transport pathways in such faults/fractures using available data is a critical issue vis-à-vis the safety assessment of radioactive waste disposal. In this study, faults in deep siliceous mudstones with low swelling capacity are investigated using cross-hole hydraulic and tracer tests between two boreholes. The water pressures observed during the hydraulic test are reproduced via hydraulic simulations, assuming a one-dimensional (1D) flow channel with a length 8–80 times the linear distance (4.5 m) between the two borehole test sections. This flow channel length indicates a tortuosity remarkably higher than that previously reported in discrete fracture network simulations and laboratory experiments using a single fracture (i.e. 1–5). Advection–dispersion simulations using a pipe model with a tortuosity of 8–80 reproduces a time series of tracer concentrations observed during the tracer test. The radius of the pipe simulated in the tracer test was 7–39 times the flow channel radius estimated via the hydraulic test, which is in agreement with the ratio of 5–20 previously reported based on in situ tracer and hydraulic tests of faulted/fractured rocks. The simulated longitudinal dispersivity is 1/9–1/20 of the estimated flow path lengths, in agreement with the laboratory and field tracer study values. These results indicate that transport pathways in faults with low hydraulic connectivity can be modelled using a highly tortuous 1D pipe flow path.

Shear-induced permeability evolution of natural fractures in granite: Implications for stimulation of EGS reservoirs

Permeability evolution of natural fractures during shearing is one of the critical issues in enhanced geothermal system (EGS). In this study, we conducted a series of numerical simulations of shear-flow tests under different normal stresses to investigate the permeability evolution and shear behavior of natural fractures during shearing. All numerical simulations in this study are executed based on a coupled hydro-mechanical pore network model (PNM) for fluid flow within the discrete element method (DEM). The numerical model uses a 33 mm × 25 mm fracture surface profile extracted from X-ray computed tomography scanning data of joints in a rock core retrieved from a 4.2-km-deep well at the Pohang EGS site. The results demonstrate a positive correlation between fracture permeability and shear displacement when the normal stress is relatively high. The central aspect of permeability evolution lies in the variation of local aperture distribution along the pathway: an increase in the variance of fracture aperture distribution leads to an increase in fracture permeability. Permeability evolution of fractures is significantly affected by normal stress, fracture roughness, and relative flow direction. Larger fracture roughness facilitates the formation of high-permeability pathways. Higher local normal stress often corresponds to lower local permeability. Moreover, high normal stress amplifies the effect of fracture roughness on permeability evolution. These findings enhance our comprehensive understanding of hydraulic-mechanical coupling effects during EGS stimulation.

Coarse-Grained Molecular Dynamics Simulations of Nanoscale Roughness Effects on Oil Film Delamination

In boundary lubrication, the detachment of lubricant molecules from a solid surface is likely to occur due to the presence of high compressive normal stress combined with shear stress exerted on the solid–liquid interface. This phenomenon often results in a delamination behavior at the interface. We aim to investigate the nanoscale roughness effect on the oil film delamination from sliding iron surfaces with grain boundaries by coarse-grained molecular dynamics simulations. As a result, the oil film delamination was effectively suppressed in higher roughness. Two distinct mechanisms of delamination were found depending on surface roughness when the critical normal stress is exceeded. High roughness enhanced the ability to prevent complete slip but had negligible influence on partial slip.Graphical

Frictional Properties and Healing Behavior of Tectonic Mélanges: Implications for the Evolution of Subduction Fault Zones

AbstractThe frictional velocity dependence and healing behavior of subduction fault zones play key roles in the nucleation of stick‐slip instabilities at convergent margins. Diagenetic to low‐grade metamorphic processes such as pressure solution are proposed to be responsible for the change in frictional properties of fault materials along plate interfaces; pressure solution also likely contributes to the acceleration of healing according to previous studies. Here, we report friction studies for temperatures of 20–100°C and normal stresses from 20 to 125 MPa on samples collected from ancient subduction fault zones, the Lower Mugi and Makimine mélanges of the Cretaceous Shimanto belt. The two mélanges correspond to the updip and downdip limits of the seismogenic zone and include deformation features that indicate lower and higher degrees of pressure solution. Our data show that the Lower Mugi mélange exhibits velocity‐weakening to velocity‐neutral frictional behavior under low normal stress and that the Makimine mélange sample shows velocity‐strengthening behavior under high normal stress. We suggest that mineralogical changes due to diagenesis and metamorphism influence fault slip behavior. We measure frictional healing in slide‐hold‐slide experiments for the Lower Mugi mélange sample and document the role of pressure solution in fault healing. Our results show that frictional healing increases at higher temperatures. The microstructures related to pressure solution found in the post‐experimental gouges support the idea that the enhanced healing is related to pressure solution.

Mechanical effects of nanomaterials on the residual shear strength of dry sandy mixtures: Implication for the high mobility of rock avalanches

Nanoparticles found in rock avalanches and natural faults were inferred to be the reason for the ultra-low shear resistance of the materials along the shear surface. Nevertheless, this inference has not been physically verified yet. To investigate the role of nanoparticles in the shear behavior of granular materials, we conducted a series of ring shear tests on silicon dioxide nanoparticles (SN), silica sand (S8), and mixtures of the S8 with different contents of SN, under varying normal stresses (σ) and shear velocities (V). Our results showed that the shear strength (μ) of SN is high when σ is small (≤ 215 kPa at our test range), even though the maximum shear velocity is about 210 cm/s, but shows a great decrease under higher σ (≥ 619 kPa). The shear strength of mixtures varied with SN content. For S8 (M0) and the mixture of 10% SN (M10), when sheared under small σ, μ first decreased slightly with increasing V when V is smaller than 1 cm/s, after that it increased slightly with further increase of V. Nevertheless, this kind of shear-rate dependent behavior was not observed in the tests under higher σ. When the content of SN in the mixture was <20%, μ increased with the increase of SN content. However, with further increase of SN content, μ decreased. Under high normal stress conditions, distinctive powder rolls were observed on the shear surface formed on the tests. When the mixtures with lower SN content (≤50%), the powder rolls were not observed. We inferred that powder rolls can be produced under high SN content and high normal stress conditions, and this structure altered the particle movement mode from sliding friction to rolling resistance, resulting in a significant decrease in the shear strength. These findings provide valuable insights into the shear behavior of granular materials with nanoparticles and then provide evidence for a better understanding of the high mobility of rock avalanches.

A comparative study of progressive failure of granite and marble rock bridges under direct shearing

Shear failure of rock bridges is an important process in geological phenomena, including landslides and earthquakes. However, the progressive failure of natural rock bridges has not yet been fully understood. In this work, we carried out direct shearing experiments on both granite and marble rock bridges, and applied acoustic emission (AE) monitoring throughout the experiments. With the mechanical curves and the evolution of AE activity (including AE energy rate and b value), the failure of rock bridges can be divided into three pre-failure phases and one ultimate failure phases. We analyzed the effects of normal stress and lithology on the pre-failure phases. We noted that with the increasing of normal stress, the length of stable cracking phase decreases and the length of unstable cracking phase slightly increases, except for marble rock bridges at high normal stress, which maintains a great proportion of stable cracking phase that possibly results from the great off-fault damage. Increasing normal stress also suppresses the dilation of granite rock bridges, but has a different effect on marble rock bridges, which also suggests the effect of lithology on failure modes.

Crystallographic micro-mechanism of faceted crack initiation in near-α titanium alloy Ti6321 under room-temperature fatigue and dwell fatigue loadings

Crack initiation mechanism of dwell fatigue has always been a key problem in rationalizing the dwell effect, and it is not completely understood yet. This study conducted stress-controlled low-cycle fatigue and dwell fatigue tests on Ti-6Al-3Nb-2Zr-1Mo alloy with bimodal microstructure to reveal its microstructural characteristics and crack initiation mechanisms. The study demonstrated that the faceted primary α nodules located near the specimen surface acted as crack initiation sites during both fatigue and dwell fatigue tests. Slip trace analysis revealed that faceted cracking occurred at (0001) basal plane with the maximum Schmid factor value through a special cracking mode referred to as (0001) twist boundary cracking. Innovative criteria of parameters C1 and C2 were proposed based on experimental observation and molecular dynamics simulations, which well identify candidates for (0001) twist boundary crack nucleation. It demonstrated that grain pairs combining a moderately high Schmid factor for basal slip and a well-orientated Burgers vector in the out-of-surface plane was the preferable location for surface (0001) twist-boundary crack initiation, and grain pairs combining a high Schmid factor for basal slip and a high normal stress on basal plane are perfect candidates for subsurface cracking. Based on this, phenomenological models are proposed to explain the surface (0001) twist-boundary cracking mechanism from the perspective of surface extrusion-intrusion-induced micro-notches.

The effect of temperature on injection-induced shear slip of laboratory faults in sandstone

Fluid injection into subsurface reservoirs may cause existing faults/fractures to slip seismically. To study the effect of temperature on injection-induced fault slip, at a constant confining pressure of 10 MPa, we performed a series of injection-induced shear slip experiments on critically stressed sandstone samples containing saw-cut fractures (laboratory-simulated faults) under varying fluid pressurization rates (0.1 and 0.5 MPa/min, respectively) and temperatures (25, 80, and 140 °C, respectively). At 25 °C, slow fault slip events with a peak slip velocity of about 0.13 μm/s were observed on a tested sample in response to a low fluid pressurization rate of 0.1 MPa/min. In contrast, fluid injection with a high pressurization rate of 0.5 MPa/min caused fault slip events with a peak slip rate up to about 0.38 μm/s. In response to a given fluid pressurization rate, several episodes of slip events with a higher slip velocity were induced at an elevated temperature of 140 °C, indicating an appreciable weakening effect at elevated temperatures. We also experimentally constrained the rate-and-state frictional (RSF) parameters at varying effective normal stresses and temperatures by performing velocity-stepping tests. The obtained RSF parameters demonstrate that for a relatively high normal stress, increasing temperature tends to destabilize fault slip. Post-mortem microstructural observations reveal that elevated temperatures promote the generation of abundant fine-grained gouge particles associated with injection-induced shear slip. Our experiments highlight that injection-induced fault slip is affected by temperature-related wear production over the fault surface.

Determining the optimal sampling interval for 3D morphology measurements of different-sized natural rock joints

Efficiently studying the scale effect of surface roughness and peak shear strength of natural rock joints, especially unfilled and well-matched ones, requires an optimal sampling interval to realize cost-effective three-dimensional morphology measurements for different-sized natural rock joints with advanced non-contact optical devices. However, rationally determining such an optimal sampling interval remains controversial. To this end, inspired by digital signal processing, the optimal sampling interval is creatively determined by Shannon's sampling theorem using the Fourier series' optimum order. An empirical formula relating the joint size to the optimum order is correspondingly developed. The proposed empirical formula was found to work well under conditions of high normal stress, where the relative errors for the surface roughness and peak shear strength of series-sized natural rock joints were mostly less than 10% and 5%, respectively, but should be used cautiously under conditions of low normal stress. Furthermore, different from previous perceptions, a higher joint roughness level was discovered to not necessarily imply the need for a smaller optimal sampling interval, and conversely. The proposed empirical formula can facilitate the determination of the optimal sampling interval for measuring different-sized natural rock joints' surface morphologies in engineering practice.

Mechanical resistance behind fiber-reinforced polymer pile: Role of clay minerals

Due to the geotechnical design requirements of the fiber-reinforced polymer (FRP) pile embedded in clay, interface friction evolution between the FRP pile and clay plays a crucial role in determining the pile shaft resistance. It is observed from the experimental evaluation that the earth pressure and shear rate affect the pile-soil interface behavior. In this study, a cross-linked epoxy resin is created to contact a siloxane surface of kaolinite in the molecular dynamic simulation. The interfacial accommodation between kaolinite and epoxy resin is studied. In order to investigate the effect of normal stress and sliding velocity on nanoscale friction characteristics, the steered molecular dynamics is utilized to simulate the sliding of the kaolinite model on the surface of the epoxy resin. Simulation results show that the calculated peak interface shear coefficient decreases nonlinearly as the normal stress increases, which follows a logarithmic relationship consistent with the FRP-soil interface shear test. On the other hand, it is observed that two distinct velocity regions, slow pulling mode (5–200 m/s) and fast pulling modes (300–800 m/s), are well fitted by extended Bell theory. The stick–slip motion is only found in slow sliding velocity mode. This increasing tendency of the energy barrier with the normal stresses indicates that higher pulling forces are required for the FRP to slide along the soil at higher normal stress. The present work provides a fundamental understanding of the friction mechanisms between kaolinite and epoxy resin.

Effect of Grain Size Distribution on Shear Strength Characteristic of Random Fill Material at Keureuto Dam, Indonesia

Earth-fill dams are commonly constructed by composing different geomaterials to optimally utilize local natural resources. In Indonesia, random fill materials are frequently used as a major composition in dam construction. The term random fill material originated from its broad range of grain size. Grain size distribution influences shear strength characteristics of geomaterials. There are 2 shear strength equations to model the behavior of fill material, i.e., linear Mohr-Coulomb and non-linear power curve. Two series of large scale in situ direct shear tests were performed at Keureuto Dam, Indonesia. Sieve analysis tests were performed accordingly. The random fill material was composed of cobbles, gravel, and less than 25% of sand. The stress-displacement characteristics of random fill material indicated that plastic deformation occurred at shear strain of 1% to 4%. The shear failure was reached in shear displacements of 60 – 90 mm, equivalent to shear strain of 8% – 12 %. Stress-strain relationships showed a dilative behavior indicating the random fill was in a relatively dense form. The dilatancy tends to decrease as the normal stress increases. The linear Mohr-Coulomb failure criteria and non-linear power curve equation are suggested to characterize the shear strength of the random fill material. To obtain a realistic value of the non-cohesive strength parameter of granular material, the Mohr-Coulomb approach should be intercepted at zero. A relationship between secant friction angles for different normal stresses is presented. This angle tends to decrease at higher normal stresses.

Thermal efficiency of stick slip events along experimental analog faults

Most of the elastic energy released by earthquakes is believed to convert into heat; however, the reported experimental thermal efficiencies, defined as the ratio of frictional heat to elastic energy, are largely scattering, i.e., 50% or 90%. In this study, we conducted double direct shear experiments using halite powders as fault gouge under normal stresses of 10, 20, 30, 40, and 50 MPa to investigate the thermal efficiency of stick slip events. The results revealed two types of temperature changes during stick slip, resulting from stress drop and frictional heating. The temperature change caused by stress drop reduced thermal efficiency by 10%–20%. The scaling relationships between the friction heat, displacement and normal stress were also determined, which bridge the gap between the previous experimental conditions with only low and high normal stresses. The thermal efficiency was 50%–85%, and the specific value was inversely proportional to the fraction of stress drop. The thermal efficiencies was not a constant value and was closely related to the coseismic stress variation. The findings of this study suggest that the widely assumed 90% earthquake heat fraction is a consequence of specific stress change conditions.

Determination of the minimum number of specimens required for laboratory testing of the shear strength of rock joints

The shear strength of rock joints is critical in determining rock mass stability. However, the reliability of shear strength determined by testing only a few rock joint specimens is questionable due to the inherent heterogeneity of rock joints. This study aimed to investigate shear strength heterogeneity and determine the required minimum number of specimens (RMN) for obtaining reliable values. Specimens were extracted from various positions within a natural rock joint, and their roughness and shear strength variations were examined. A significant correlation between shear strength heterogeneity and joint roughness was found. Monte Carlo simulation was used to simulate engineering practice sampling procedures. The effectiveness of specimen numbers under different normal stresses was evaluated using relative error and corresponding probability. Results showed that the RMN depended on acceptable relative error, specified probability, and normal stress. For acceptable relative errors of 5% to 10% and corresponding probabilities of 85–95%, the RMN exhibits a decrease with an increase in normal stress, while it demonstrates an increase when considering acceptable relative error and probability requirements. A smaller RMN was needed under high normal stress for the same rock joint, demonstrating a decrease in shear strength heterogeneity with increasing normal stress. However, commonly used specimen numbers like 3 or 5 did not always align with the recommended RMN. The results also emphasize the significance of considering rock material properties when determining the RMN. The proposed method provides a quantitative and reliable tool for determining the RMN, considering the heterogeneity of rock joints.

On the tool wear mechanism of machining Zr-based bulk metallic glasses under varying corner radii

Revealing the tool wear mechanisms of machining Zr-based bulk metallic glasses (BMGs) is important for the processing of BMGs in engineering applications. The tool wear mechanisms of machining BMGs with PCBN tools under varying corner radii were investigated, and the results shown that the adhesive and oxidation wear were the main wear mechanisms. The low thermal conductivity of the BMG workpiece material increased the cutting temperature. The effect of corner radius on tool wear mechanism was characterized by the normal stress fields. It indicated that the extremely high maximum normal stress was the main reason for edge chipping. Finally, the influence of tool wear state on machined surface quality was related to the machined surface morphology. The findings have shown that the edge chipping and adhesive wear produced feed marks, material side flow and adhensions on the machined surface, leading to the increase of surface roughness.