Local Stress Distribution Research Articles

A simplified theoretical model to predict the shear behavior of concrete/rock joints with Gaussian irregularities

The inherent randomness in the roughness of concrete-rock joints poses challenges for analyzing their shear behaviour. Traditionally, theoretical models simplify these complex geometries by approximating them as regular triangular asperities. This study presents a novel micro-mechanical model developed to simulate the shear behaviour. The model accounts for the complex and random roughness of joint profiles by considering varying asperity heights as Gaussian distribution. Local stress distribution among individual asperities was determined. A failure envelope, mapping joint dilation against asperity height, was obtained, allowing us to identify the critical joint dilation for individual asperities at which individual asperity failure results. The parameter of shear area ratio, which captures the portion of failed asperities relative to all asperities, is introduced, and its semi-analytical solution was derived. Additionally, a wedge-shaped planar failure surface is determined based on laboratory observations and equations to estimate post-failure residual resistance is obtained. A series of direct shear tests on rock/concrete joints with a range of geometries was conducted to validate the proposed model and reasonably close agreement was obtained between predicted and measured performance. An additional case study analyzing the results of field tests on a drilled pile socketed in rock has been conducted using the proposed method. The results showed good agreement with the measured data, demonstrating the validity and practicality of the proposed approach.

Dynamic Behavior and Energy Absorption of Typical Porous Materials under Impacts.

Porous materials are known for their excellent energy absorption capability and, thus, are widely used in anti-impact applications. However, how the pore shape and size impact the failure mechanism and overall behavior of the porous materials under impact loading is still unclear or limitedly touched. Instead of using homogeneous solids for the porous material model, pores with various shapes and sizes were implanted in a solid to establish the porous materials that have true porous structures, which permits exploration of the local failure mechanism. The results revealed that differently shaped holes have two different dominant deformation modes. And due to their different local stress distributions, they enter the plastic phase earlier and, thus, have higher specific energy absorption. Meanwhile, the model changes from hardening to a quasi-zero stiffness model as the hole size increases. The application of this work can be extended into the field of impact resistance.

Microstructure and residual stress gradient evolution mechanism of electronic copper strip for lead frame

The miniaturization of integrated circuits has led to a shift in lead frame fabrication methods from physical stamping to chemical etching. However, this process is highly sensitive to residual stress. We investigated the gradient distribution of residual stress, microstructure, and macroscopic texture in electronic copper foils using a layer-by-layer peeling method, and proposed a novel strategy for evaluating residual stress levels. Our findings reveal that the rolling-induced residual stress exhibits a gradient distribution along the thickness direction. Specifically, from the surface to the central layer, the stress transitions gradually from tensile to compressive, with the stress type primarily influenced by metal flow during rolling. Additionally, we observed gradient variations in the S and Cube texture. Tensile stress favors the formation of Cube-texture, while compressive stress promotes S-texture development. Notably, Cube-texture can lead to strain localization during rolling, directly impacting the local residual stress levels and distribution. Furthermore, quantitative analysis of dislocation density using peak profile methods revealed a consistent trend between {111} plane dislocation density and lateral residual stress. Further investigation highlighted that dislocations and precipitates associated with {111} planes in face-centered cubic metals significantly influence residual stress, with their combined effects determining the overall stress magnitude in relation to texture, dislocations, and precipitates.

A machine learning–based framework for mapping hydrogen at the atomic scale

Hydrogen, the lightest and most abundant element in the universe, plays essential roles in a variety of clean energy technologies and industrial processes. For over a century, it has been known that hydrogen can significantly degrade the mechanical properties of materials, leading to issues like hydrogen embrittlement. A major challenge that has significantly limited scientific advances in this field is that light atoms like hydrogen are difficult to image, even with state-of-the-art microscopic techniques. To address this challenge, here, we introduce Atom-H, a versatile and generalizable machine learning-based framework for imaging hydrogen atoms at the atomic scale. Using a high-resolution electron microscope image as input, Atom-H accurately captures the distribution of hydrogen atoms and local stresses at lattice defects, including dislocations, grain boundaries, cracks, and phase boundaries. This provides atomic-scale insights into hydrogen-governed mechanical behaviors in metallic materials, including pure metals like Ni, Fe, Ti and alloys like FeCr. The proposed framework has an immediate impact on current research into hydrogen embrittlement and is expected to have far-reaching implications for mapping "invisible" atoms in other scientific disciplines.

Mechanical response of LPBFed TI64 thickness graded Voronoi lattice structures

The possibility to realize Additively Manufactured functionally graded lattice structure based on Voronoi tessellation enormously increases the possibility in tailoring the stiffness, mechanical properties and energy absorption capacity of the samples. The work presents the design and mechanical characterization of functionally thickness graded Voronoi lattice structures in comparison with constant thickness lattice structures for the evaluation of mechanical performance and energy absorption capacity. Firstly, the design and laser power bed fusion process are detailed. The dimensional deviation between designed models and Ti6Al4V specimens is quantified to assess the samples’ quality. Their mechanical performance is analyzed by quasi-static compression experimental tests, supported by numerical analysis for the evaluation of local stress distributions and deformation modes. The average dimensional deviation between CAD models and fabricated samples is 0.09 mm, likeminded with the literature optimum. The structures exhibit Young Modulus values ranging between 10 MPa and 21 MPa, compatible with biomedical applications. The compressive force for thickness graded structures tends to increase up to densification, while uniform thickness structures present an almost constant value of force in the platform stage. Additionally, the energy storage changes according to the presence of thickness gradient: the larger the thickness gradient, the larger the energy absorption capacity.

Thermal and Mechanical Mechanisms of Polymer Wear at the Nanoscale.

Wear is a ubiquitous phenomenon that limits the life of many engineered components with sliding interfaces through the gradual removal of material. The wear of polymers is crucial in many applications, ranging from bearings to orthopedic implants to nanolithography processes. The wear rate of polymers is strongly affected by the stress and temperature at the interface. The effects of temperature and stress are often described empirically since the wear process involves complex interactions between multiple asperities on rough surfaces over a range of length scales. Nanoscale tribology experiments at the single-asperity level have provided new insights into the underlying mechanisms of wear. Experiments on hard covalently bonded materials, including silicon and diamond, have demonstrated that wear is an atomic attrition wear process that can be modeled using stress-assisted transition state theory. Here, we examine the wear of a common polymer, polymethylmethacrylate (PMMA), at the nanoscale as a function of stress and temperature and show that the polymer wear is controlled by a combination of atomic attrition and viscoelastic relaxation. While the wear experiments are conducted at the nanoscale via atomic force microscopy, the results show that accounting for the local stress distribution at the contact interface is critical to understanding the wear behavior, an effect that was not considered in earlier studies on hard materials. Using a model that accounts for the stress distribution, we demonstrate the ability to predict the wear volume within 8%.

High aspect ratio cellulose nanofibrils with low crystallinity for strong and tough films

Cellulose nanofibril (CNF) films with both high strength and high toughness are attractive for applications in energy, packaging, and flexible electronics. However, simultaneously achieving these mechanical properties remains a significant challenge. Herein, a multiscale structural optimization strategy is proposed to prepare high aspect ratio CNFs with reduced crystallinity for strong and tough films. Carboxymethylation coupled with mild mechanical disintegration is employed to modulate the multiscale structure of CNFs. The as-prepared CNFs feature an aspect ratio of >800 and a crystallinity of <60 %. The film prepared using CNFs with a high aspect ratio (~1100) and reduced crystallinity (~54 %) exhibits a tensile strength of 229.9 ± 9.9 MPa and toughness of 22.2 ± 1.4 MJ/m3. The underlying mechanism for balancing these mechanical properties is unveiled. The high aspect ratio of the CNFs facilitates the transfer and distribution of local stress, thus endowing the corresponding film with high strength and toughness. Moreover, the low crystallinity of the CNFs permits the movement of the cellulose chains in the amorphous regions, thereby dissipating energy and finally increasing the film toughness. This work introduces an innovative and straightforward method for producing strong and tough CNF films, paving the way for their broader applications.

High-resolution measurement of contact stresses and friction in indentation and machining by full-field photoelasticity

An experimental study has been made of the sliding plastic contact in wedge indentation and machining of ductile metals. The use of full-field photoelasticity has allowed direct determination of interface pressure and shear stress distribution along the tool (indenter) and workpiece sliding contact at micron-scale resolution. Sapphire, a transparent photoelastic material that possesses sufficiently high hardness to indent and machine metals, is used as the tool material. It is shown that the Coulomb friction model applies only at the edges of the contact where the interface pressure falls below a certain value associated with the material's flow stress. Within the plastic contact zone, the mode of friction as well as the relationship between interface pressure and shear stress are very complex. In both cases, it is shown that shear stress neither remains constant nor varies in proportion to the pressure. It is proposed that the complex nature of friction and stress field at the sliding contact can be understood through simultaneous observations of the metal plastic flow at and near the interface. Using in situ measurements of the velocity field near the interface and local stress distribution at the contact from photoelasticity, friction contribution to the overall work is calculated and shown to be substantial (greater than one-third) in the case of machining.

Impact of screw tip design on screw anchorage: mechanical testing and numerical simulation

BackgroundScrew loosening is a commonly reported issue following spinal screw fixation and can lead to various complications. The initial cause of screw loosening is biomechanical deterioration. Previous studies have demonstrated that modifications in screw design can impact the local biomechanical environment, specifically the stress distribution on bone-screw interfaces. There are several different designs of screw tips available for clinically used pedicle screws; however, it remains unclear whether these variations affect the local stress distribution and subsequent screw anchorage ability.MethodsThis study conducted comprehensive biomechanical research using polyurethane foam mechanical tests and corresponding numerical simulations to investigate this topic. Models of pedicle screw-fixed osteoporotic polyurethane foam were created with two different clinically used screw tip designs (flat and steep) featuring varying tip lengths, taper angles, and diameters, as well as identical flank overlap areas and thread designs. The anchorage ability of the different models was assessed through toggle and pull-out test. Additionally, numerical mechanical models were utilized to compute the stress distributions at the screw and bone-screw interfaces in the different models.ResultsMechanical tests revealed superior anchorage ability in models utilizing flat-tipped screws. Furthermore, numerical modeling indicated improved anchorage ability and reduced stress concentration tendency in these models.ConclusionChanges in screw tip design can significantly impact the biomechanical anchoring capability of screws. Specifically, flatter tip pedicle screws may mitigate the risk of screw loosening by alleviating stress concentration on bone-screw interfaces.

Large Local Internal Stress in an Elastically Bent Molecular Crystal Revealed by Raman Shifts.

The structural dynamics involved in the mechanical flexibility of molecular crystals and the internal stress in such flexible materials remain obscure. Here, the study reports an elastically bending lipidated molecular crystal that shows systematic shifts in characteristic vibrational frequencies across the bent crystal region - revealing the nature of structural changes during bending and the local internal stress distribution. The blueshifts in the bond stretching modes (such as C═O and C-H modes) in the inner arc region and redshifts in the outer arc region of the bent crystals observed via micro-Raman mapping are counterintuitive to the bending models based on intermolecular hydrogen bonds. Correlating these shifts with the trends observed from high-pressure Raman studies on the crystal reveals the local stress difference between the inner arc and outer arc regions of the bent crystal to be ≈2GPa, more than an order of magnitude higher than the previously proposed value in elastically bending crystals. High local internal stress can have direct ramifications on the properties of molecular piezoelectric energy harvesters, actuators, semiconductors, and flexible optoelectronic materials.

Investigation of the Mechanical Strength of Artificial Metallic Mandibles with Lattice Structure for Mandibular Reconstruction.

Mandibular reconstructive surgery is necessary for large bone defects. Although various reconstruction methods have been performed clinically, there is no mandibular reconstruction method that meets both sufficient strength criteria and the patient's specific morphology. In this study, the material strength of the cylindrical lattice structures formed by electron-beam melting additive manufacturing using titanium alloy powder was investigated for mandibular reconstruction. The virtual strengths of 28 lattice structures were compared using numerical material tests with finite element method software. Subsequently, to compare the material properties of the selected structures from the preliminary tests, compression test, static bending test and fatigue test were conducted. The results showed that there were correlations with relative density and significant differences among the various structures when comparing internal stress with deformation, although there was a possibility of localized stress concentration and non-uniform stress distribution based on the lattice structure characteristics. These results suggest that the lattice structure of body diagonals with nodes and a cell size of 3.0 mm is a potential candidate for metallic artificial mandibles in mandibular reconstruction surgery.

Making stress visible: A method to quantify local stress distribution in metals using digital image correlation method

Stress (force) induces the deformation of materials. Stress distribution in materials is generally heterogeneous depending on their shapes and microstructures, which governs their global deformation and failure, and sometimes stress concentration induces serious incidents in society. However, it has been challenging to experimentally quantify stress distributions in materials in macro- and micro-scales by now. Here, we newly propose and establish a simple but promising method to quantify local stress distributions in materials by applying the digital image correlation (DIC) technique, which is applicable to all length scales. We expect that the newly developed method would become the first step to give an impact on fundamentally understanding the deformation and fracture of materials in various scales as well as on practically reducing risks in structural components.

Simple double shooting approach with bisection for FRCM reinforced curved masonry prisms subjected to shear

In this study, curved masonry pillars reinforced with FRCM subjected to standard shear tests are analyzed through a novel mono-dimensional model, where failure is governed by Mode II. Three approaches with different accuracy are proposed: i) the first, where the outer matrix is neglected; ii) the second, where the inner matrix is assumed rigid; and iii) the third which considers both matrix layers. Matrix and fiber are assumed subjected to a monoaxial state of stress and exchange tangential stresses at the interfaces. The load is applied by incrementing the displacement at the free fiber edge. Material properties of matrix, fiber and interfaces are assumed constant on small portions of the bonded length. Non-linearity is considered penalizing the elastic modulus using the results of the previous time step. The substrate is assumed rigid. The substrate curvature influence is manifested through interface normal stresses, incorporated into the bond-slip constitutive behavior via the Mohr-Coulomb law. The normal stresses can be determined by enforcing radial equilibrium. For the first two models, the field problem is constituted by a system of two 2nd order differential equations into two variables, namely the displacement of the inner (or outer) layer of mortar and of the fiber textile. A 1D shooting is employed, after having converted the boundary value problem (BVP) into an initial value one (IVP), being the latter fully explicit. For the third model, the field problem is constituted by a system of three 2nd order differential equations, and an additional displacement variable is introduced, necessitating a 2D shooting. The validation is carried out through comparisons with existing experimental data. Good predictions of the load-slip curves, for different strengthening configurations (extrados and intrados with two curvature radii), are observed. In addition, an insight into local stress distributions and material degradation for matrix layers and interfaces is obtained.

Experimental study on bond behavior between wet lay-up CFRP and corroded steel plates

Corrosion of steel in marine environments is a major safety concern for marine steel structures throughout their service lives. Strengthening these corrosion-damaged structures with carbon fiber-reinforced polymer (CFRP) shows great potential for extending their service lives. However, the bond behavior between CFRP and corroded steel, especially the influence from adhesive properties and corrosion degree, has not been fully understood. This paper therefore presents the results of a comprehensive experimental study on the bond behavior between wet lay-up CFRP and corroded Q355B steel plates. Tensile tests on double-lap CFRP-to-steel joint specimens with different bonded lengths, adhesives and corrosion durations were then conducted. The failure modes, load-displacement curves, strain and local shear stress distributions, effective bond lengths, and bond-slip relationships of the test joint specimens were investigated in detail. The result showed that the influence of corrosion on the CFRP-to-steel bond performance varied depending on the failure modes resulting from the material properties of adhesives. However, corrosion has insignificant influence on the general patterns of load-displacement curves, strain distribution, local shear stress distribution, local bond-slip curves with same adhesives. When failure occurred in the adhesive or the steel-adhesive interface, the corrosion tended to have a more accentuated effect on the bond performance.

Raman spectroscopic stress mapping of single high modulus carbon fibre composite fragmentation in compression

Fragmentation of high modulus carbon fibres is relevant to the failure mechanisms of advanced polymer matrix composites in compression. In situ spatially-resolved Raman spectroscopy during the fragmentation of model single fibre composites is used to map local stress distributions during failure events. The characteristic graphitic band (the G band) located around 1580 cm−1 is associated with the in-plane carbon-carbon bonds; this band shifts its position, and can be calibrated, with the local axial stress in the fibre. The analysis maps the evolution of local stresses with increasing overall composite compression strain, identifying a series of critical events, including fibre fracture, interfacial debonding, and the formation of inter-fragment ‘wedges’. Fitting shear lag models provides interfacial shear strength values. Multiple failure maps of two examples of high modulus PAN carbon fibres (M46J and M55J) demonstrate the possibility of local fragment bending due to fragment end contact. A timeline of potential fragmentation events is proposed for carbon fibres undergoing compression.

Extending the intermedullary nail will not reduce the potential risk of femoral head varus in PFNA patients biomechanically: a clinical review and corresponding numerical simulation

Femoral head varus is an important complication in intertrochanteric fracture patients treated with proximal femoral nail anti-rotation (PFNA) fixation. Theoretically, extending the length of the intramedullary nail could optimize fixation stability by lengthening the force arm. However, whether extending the nail length can optimize patient prognosis is unclear. In this study, a review of imaging data from intertrochanteric fracture patients with PFNA fixation was performed, and the length of the intramedullary nail in the femoral trunk and the distance between the lesser trochanter and the distal locking screw were measured. The femoral neck varus status was judged at the 6-month follow-up. The correlation coefficients between nail length and femoral neck varus angle were computed, and linear regression analysis was used to determine whether a change in nail length was an independent risk factor for femoral neck varus. Moreover, the biomechanical effects of different nail lengths on PFNA fixation stability and local stress distribution have also been verified by numerical mechanical simulations. Clinical review revealed that changes in nail length were not significantly correlated with femoral head varus and were also not an independent risk factor for this complication. In addition, only slight biomechanical changes can be observed in the numerical simulation results. Therefore, commonly used intramedullary nails should be able to meet the needs of PFNA-fixed patients, and additional procedures for longer nail insertion may be unnecessary.

Interpretation of Frequency Effect for High-Strength Steels with Three Different Strength Levels via Crystal Plasticity Finite Element Method.

The fatigue behavior of a high-strength bearing steel tempered under three different temperatures was investigated with ultrasonic frequency and conventional frequency loading. Three kinds of specimens with various yield strengths exhibited obvious higher fatigue strengths under ultrasonic frequency loading. Then, a 2D crystal plasticity finite element method was adopted to simulate the local stress distribution under different applied loads and loading frequencies. Simulations showed that the maximum residual local stress was much smaller under ultrasonic frequency loading in contrast to that under conventional frequency at the same applied load. It was also revealed that the maximum local stress increases with the applied load under both loading frequencies. The accumulated plastic strain was adopted as a fatigue indicator parameter to characterize the frequency effect, which was several orders smaller than that obtained under conventional loading frequencies when the applied load was fixed. The increment of accumulated plastic strain and the load stress amplitude exhibited a linear relationship in the double logarithmic coordinate system, and an improved fatigue life prediction model was established.

Combined effect of random porosity and surface defect on fatigue lifetime of additively manufactured micro-sized Ti6Al4V components: An investigation based on numerical analysis and machine learning approach

Surface defects and internal porosities resulting from the additive manufacturing process contribute to a scatter in fatigue lifetime, increasing uncertainty in applications such as aerospace engineering. This study proposes a combined approach of machine learning and finite element modelling to explore the interaction between random porosity distribution and high surface roughness on the fatigue lifetime of micro-sized additively manufactured parts. To achieve this, a high-fidelity finite element model is constructed with randomly distributed porosities and surface defects. A fatigue lifetime estimation model, developed using a combination of continuum damage mechanics and the theory of critical distance, is then applied to predict lifetime using effective stress extracted from simulations. A total of 1200 simulations are conducted using these models to examine the interaction effects of subsurface porosity and surface defects on localized stress distribution and fatigue lifetime. Subsequently, two machine learning algorithms, Support Vector Regression and Kernel Ridge Regression, are employed to estimate fatigue lifetime, accounting for the effects of randomly distributed subsurface porosities and surface defects. Eighty percent of the developed finite element models are employed to construct an input dataset, incorporating geometrical features of pores, and to train the algorithms, while the remaining 20% are reserved for verification purposes. The observed results demonstrate that the combined effect of random porosity and surface defects increases fatigue scatter behaviour, leading to greater uncertainty in lifetime prediction. Furthermore, the machine learning algorithms exhibit promising prediction performance.

Equivalent characterization of initial crack size of blunt notched components based on test data and physical model

The precise definition of initial crack size applicable to fracture mechanics is crucial for predicting the total fatigue life of structural components. Given that the demarcation between crack formation and crack propagation depends not only on the material but also on the stress level, theoretical and experimental procedures for defining the crack boundary point are developed. Underlying the procedure is that the designed notched members have the same local stress distribution as the structure. Consequently, the fatigue life and initial crack size of S355J2 steel notched components with different scales but similar stress fields were predicted and compared with experimental data. Results show that fatigue life predictions fall within ±2 factor band, and the crack initiation size obtained by AM is closest to the experimental results, with a difference of less than 30.2%, which proves that the approach of treating the initial crack size as a function related to fatigue life and fatigue notch factor is reasonable.

Enhancing Wind Turbine Blade Preventive Maintenance Procedure through Computational Fluid Dynamics-Based Prediction of Wall Shear Stress

Wind turbine blades are essential parts of wind energy systems and are frequently exposed to harsh environmental elements, such as strong winds, turbulence, and corrosive atmospheric elements. Over time, these circumstances may result in serious harm to blades, such as delamination and erosion, which may negatively affect the wind turbine’s functionality and durability. Accurate prediction of various types of damage is crucial to improve the toughness and lifespan of wind turbine blades and to maximize the overall effectiveness of wind energy systems. This article presents a novel computational fluid dynamics (CFDs)-based method for analyzing the distribution of wall shear stress on turbine blades, aimed at publicizing the yearly maintenance procedure. The investigation results from the CFDs, when compared with the current situation in a wind turbine farm in Thailand, confirmed that our wall shear stress modeling accurately predicted wind turbine damage. A maximum wall shear stress level higher than 5.00 Pa in the case of PA 90°, incoming air velocity 10.00 m/s, and 15 rpm was the main contribution to presenting the erosion and delamination from current drone inspection in wind turbine farms. In conclusion, these findings demonstrated the potential of using CFDs to predict wind turbine blade delamination and erosion, thereby significantly contributing to the development of specific and accurate yearly preventive maintenance. The proposed CFDs-based approach should serve as a sustainability tool for local human development, benefiting wind turbine engineers and operating technicians by providing them with a deeper understanding of the local flow conditions and wall shear stress distribution along wind turbine blades. This enables them to make informed decisions regarding blade design and maintenance.