Failure Mechanisms Research Articles

Performance of glass epoxy composites under combined effect of in‐plane fiber waviness with circular cutout through tensile test, and image processing technique

AbstractPresent study comprehensively explores the phenomenon of in‐plane fiber waviness in glass/epoxy fiber reinforced polymer (GFRP) composites. Utilizing a pioneering technique that employs a semi‐circular bar to induce controlled fiber waviness, coupled with image processing using OpenCV library in Python coding for precise measurement and analysis of in‐plane fiber waviness. This defect is commonly found in components fabricated with fiber‐reinforced composites. During the process of manufacturing fibers may deviate from their intended orientation due to process variables or resin flow dynamics. Understanding in‐plane fiber waviness is crucial due to its impact on mechanical properties of composites. It is essential for optimizing manufacturing processes and ensuring enhanced structural performance in diverse engineering applications through analysis of strength and failure mechanism. A novel study was conducted by introducing a circular cutout within the fiber waviness region to investigate the combined effect of multiple defects. The experimental tensile test reveals that as waviness ratio (WR) increases a significant decrease in its tensile strength and vice versa. The study incorporates scanning electron microscopy (SEM) image analysis to examine composite failure. By advancing the understanding of in‐plane fiber waviness and its implications, this research significantly contributes to ongoing efforts in composite design and optimization.Highlights Adopting a cutting‐edge method to create controlled fiber waviness that makes use of a semi‐circular bar. Image processing with Python code that makes use of the OpenCV package to precisely measure and analyze in‐plane fiber waviness. A new investigation was carried out to examine the combined effect of multiple flaws by creating a circular cutout within the fiber waviness zone.

Compressive behaviors and deformation mechanism of carbon fiber reinforced epoxy composites: A microscopic and molecular dynamics perspective

AbstractInvestigating the macro‐mechanical properties of polymer composites at the nanoscale is a challenging topic. Here we report the compressive performances of carbon fiber‐reinforced epoxy composites using molecular dynamics (MD) simulations. The evolution of microstructure and microscopic energy, including free volume, radius of gyration, dihedral angle, potential energy, and interaction energy, has been investigated to characterize compressive behaviors at the nanoscale. Molecular chains gradually bend, and the movement space of the molecular chains decreases during compression loading. The radius of gyration and dihedral angle are deformed into a state of irreversible plasticity to accommodate the microstructural transformation. The interaction energy increases and subsequently declines as the carbon fiber/epoxy interface gets closer, reflecting the transition of the internal structure. The inhomogeneity and interfacial concentration distribution of stress, and local molecular stiffness under various strains have been obtained to reveal the nanoscopic mechanism of epoxy failure and interface delamination during compression. This study reveals the compression behaviors and deformation mechanism of carbon fiber‐reinforced epoxy composites at the molecular level, providing directions and possibilities for molecular design and structural optimization of composites.Highlights The nanoscopic compression deformation of CFRP composites is studied. Microstructural evolution and conformation transformation are revealed. The evolution and transition of microscopic energy are analyzed. Micro‐mechanism of epoxy deformation and interface delamination is elucidated.

Elastic properties of 3D printed clavicles are closer to cadaveric bones of elderly donors than commercial synthetic bones

Synthetic bone models have increasing utility in orthopaedic research due to their low cost and low variability and have been shown to be biomechanically equivalent to human bones in a variety of ways. The rise in additive manufacturing (AM) for orthopaedic applications presents an opportunity to construct synthetic whole-bone models for biomechanical testing applications, but there is a lack of research comparing these AM models to cadaveric or commercially available bone surrogates. This study compares the mechanical properties of 3D printed clavicle models to commercially available (4th generation Sawbones) and human cadaveric clavicles via nondestructive cyclic 4-point bending, axial compression, and torsion, and a final axial compression test to failure. Commercially available synthetic clavicles had 57.8–203% higher superior-inferior bending rigidity (p < 0.0001), 80.9–198% higher axial stiffness (p < 0.001), and 314–557% higher torsional rigidity (p < 0.05) on average than AM and cadaveric clavicles. Cadaveric and AM clavicles printed from a BoneMatrix/VeroWhite composite material had similar failure mechanisms under axial compression while AM VeroWhite clavicles experienced catastrophic failure, but these groups did not have significantly different ultimate failure loads. Together, these results demonstrate that current commercially available synthetic clavicles may be too rigid to emulate the mechanical properties of elderly cadaveric clavicles, and that AM bone models can closely mimic these cadaveric bones in a variety of biomechanical loading schemes. These results show promising applications for future work using 3D printed bone surrogates for biomechanical analysis of orthopaedic implants and other surgical repair techniques.

Investigation on internal evolution process of slope under seismic loading: insights from a transparent soil test and shaking table test

Earthquakes are a primary factor in triggering slope instability and pose a serious threat to transportation. However, current research on the internal deformation of slopes under seismic loading remains limited. To investigate the effects of different seismic loadings on the evolution process and failure mode of slopes, a novel experiment combining transparent soil materials and shaking table tests was proposed in this study. Using a self-designed shaking table system, sine waves with amplitudes of 0.10 g, 0.15 g, and 0.20 g and frequencies of 3 Hz, 5 Hz, and 8 Hz were applied. Based on Particle Image Velocimetry (PIV) technology and non-intrusive monitoring techniques, displacement and velocity contour maps, whole-field average displacement and failure mechanism of the slope were analyzed. The results show that, as the vibration persists, the slope transitions from initial shallow linear sliding to overall circular arc sliding, exhibiting an obvious progressive traction failure mode. The evolution process of the slope could be divided into three phases: shallow low-speed sliding phase, overall rapid sliding phase, and overall low-speed sliding phase. Furthermore, the amplitude of seismic loading has a greater influence on slope deformation compared to its frequency. This novel experiment offers important insights into the internal evolution process of slopes under seismic loading.

Cracking evolution and failure mechanism of brittle rocks containing pre-existing flaws under compression-dominating stresses: Insight from numerical approach

Comprehending the cracking evolution and failure mechanism of flawed rocks under compression-dominating stresses is essential to evaluating the stability of rock engineering. In this work, a newly developed geometry-constraint-based non-ordinary state-based peridynamic (GC-NOSBPD) theory that can eliminate the numerical oscillation is applied to predict the development of new cracks of flawed rocks under compression-dominating stresses. The failure of bonds between particles is judged by the bond-associated stress-based fracture criteria. The cracking evolution trajectories of semi-disc and disc specimens containing flaws are traced. The effects of flaw inclination angle on the cracking trajectories are analyzed. The cracking evolution paths of rock-like specimens with two flaws under uniaxial and biaxial compression are molded. The effects of confining stress on the growth of new cracks are investigated. The confining stress restrains the propagation of tensile cracks, but it is easy to promote the growth of shear cracks. The concentration and transfer effects of stress can plainly revel the failure mechanism of flawed rocks. The present numerical method is reasonable to predict the tensile and shear failure modes of flawed specimens under compression-dominating stresses.

First-principles study on the failure and doping strengthening mechanisms at the interface of high-alumina ferritic heat-resistant steel/oxide film

This study employs first-principles calculations based on density functional theory to explore the failure mechanisms and enhancement strategies for the interface between high-aluminum ferritic heat-resistant steel and oxide film (α-Fe/Al₂O₃ interface). Establishing an interface model at the lowest-energy densely packed plane and performing tensile tests determined that fracture behavior manifests as ductile fracture at the interface. Further analysis of the charge density and differential charge density maps for various doped models confirmed the feasibility of strengthening the α-Fe/Al₂O₃ interface structure through alloy element doping. The results demonstrate that effective dopant elements (such as V, Mn, and Mo) can induce more electrons to transfer to the interface, increase electron concentration, and alter the chemical bonding nature of the interface, thereby significantly enhancing its bonding performance. This study proposes a method to enhance the interface of high-aluminum ferritic heat-resistant steel through doping, providing a theoretical foundation for further research on similar heat-resistant steel surfaces with Al₂O₃ films.

Tumor-associated macrophages/C-X-C motif chemokine ligand 1 promotes breast cancer autophagy-mediated chemoresistance via IGF1R/STAT3/HMGB1 signaling

Autophagy-mediated chemoresistance is the core mechanism for therapeutic failure and poor prognosis in breast cancer. Breast cancer chemotherapy resistance is believed to be influenced by tumor-associated macrophages (TAMs), by which C-X-C motif chemokine ligand 1 (CXCL1) is the most abundant cytokine secreted. Yet, its role in mediating autophagy-related chemoresistance is still unknown. This study aimed to explore the molecular mechanisms by which TAMs/CXCL1 induced autophagy-mediated chemoresistance in breast cancer. It was found that TAMs/CXCL1 promoted chemoresistance of breast cancer cells through autophagy activation in vitro, and CXCL1 silence could enhance the chemosensitivity of paclitaxel-resistant breast cancer cells via autophagy inhibition. A high-throughput quantitative PCR chip and subsequent target validation showed that CXCL1 induced autophagy-mediated chemoresistance by inhibiting VHL-mediated IGF1R ubiquitination. The elevated IGF1R then promoted STAT3/HMGB1 signaling to facilitate autophagy. Additionally, TAMs/CXCL1 silence improved paclitaxel chemosensitivity by suppressing autophagy in breast cancer mice xenografts, and clinical studies further linked CXCL1 to IGF1R/HMGB1 signaling, as well as shorter free survival of recurrence. Taken together, these results not only uncover the crucial role of TAMs/CXCL1 signaling in mediating breast cancer chemoresistance through enhancing autophagy, but also shed novel light on the molecular mechanism of IGF1R/STAT3/HMGB1 pathway in regulating autophagy and its impact on cancer prognosis.

Damage evolution and failure mechanism of 2.5D woven composite tubes under quasi-static lateral compression

2.5D woven composites are ideal candidate materials for deep-sea pressure tubes owing to their excellent out-of-plane properties. This paper presents the damage evolution and failure mechanism of 2.5D woven composite tubes under quasi-static lateral compression. To conduct this study, 2.5D woven composite tubes with different thickness-to-diameter ratios, 0.04, 0.07 and 0.10, were designed and prepared. The quasi-static lateral compression tests were carried out in order to evaluate the progressive damage analysis, combining high speed photographic image with acoustic emission technologies. The results show that the increase of the ratio of thickness-to-diameter, the deformation and shear failure of the sample can be inhibited obviously. Due to the enhanced interlayer interaction, the lateral stiffness of the sample is obviously improved, so the lateral bearing stability of the sample is improved. When the peak load of samples with the thickness-to-diameter ratio of 0.1 reached 11.51 kN, it exceeded that of samples with thickness-to-diameter ratios of 0.04 and 0.07 by 450% and 82%, respectively. Furthermore, the failure mechanisms of samples with the thickness-to-diameter ratio of 0.1 were controlled by delamination fracture, whereas that of 0.04 and 0.07 were mainly influenced by shear failure and delamination failure, respectively.

Development of Fiber-Reinforced Polymer Composites for Additive Manufacturing and Multi-Material Structures in Sustainable Applications

This study investigates the mechanical properties of carbon and natural fiber-reinforced Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol (PETG) composites produced via Additive Manufacturing (AM), focusing on Material Extrusion (MEX). The performance of filaments made from pre-consumer recycled PLA (rPLA) and PETG, with varying weight percentages of hemp and jute short fibers, was evaluated through tensile testing. Comparisons were made between the original filaments (PLA, carbon fiber-reinforced PLA [CF–PLA], and PETG) and their recycled versions. Multi-material compositions—neat PLA and PETG, single-graded (PLA + CF–PLA, PETG + CF–PETG), and multi-gradient (PLA + CF–PLA + PLA, PETG + CF–PETG + PETG)—were analyzed for mechanical properties. Optical microscope images of multi-material specimens were captured before and after fracture to assess failure mechanisms. The results indicate that the original CF–PETG filaments achieved a tensile strength of 50.14 MPa, which is higher than rPLA, PLA, and CF–PLA by 2%, 70%, and 6.7%, respectively. The re-manufactured PLA filaments reinforced with 7 wt% hemp fibers exhibited a tensile strength of 38.8 MPa, representing a 29% increase compared to the original PLA filaments and a 26% improvement over recycled PLA. Additionally, incorporating 7% jute fiber into PETG resulted in a tensile strength of 62.38 MPa, reflecting a 12% improvement over the original PETG filaments and a 15% increase compared to the recycled PETG filaments. Among specimens produced by AM, CF–PLA and rPLA demonstrated the highest tensile and compressive strengths. However, multi-material composites showed reduced mechanical performance compared to neat PLA and PETG, highlighting the need for improved interlayer adhesion. This study emphasizes the importance of optimizing material combinations and fiber reinforcement to enhance the mechanical properties of composites produced through AM.

Revealing interfacial degradation of Bi2Te3-based micro thermoelectric device under current shocks

Micro thermoelectric devices (micro-TEDs) offer great potential for IoT and electronic thermal management. However, they face challenges with reliability under high current densities. This study elucidates the failure mechanisms of Bi2Te3-based micro-TEDs subjected to current shocks. Experimental results indicate that at a high current density of 1800 A/cm2, the internal resistance of micro-TEDs increased by 12.9 % to 2.034 Ω. This led to a 52.0 % decrease in maximum output power at a 20 K temperature difference, dropping to 1.53 mW. Additionally, as the frequency of ON/OFF current applied to micro-TED increases, the resistance growth rate jumped from 0.764 mΩ/h for slow power cycling to 2.328 mΩ/h for fast power cycling. This indicates that higher cycling frequencies exacerbate the degradation of the device. In-situ TEM analysis revealed that current-induced elemental diffusion and electrical stress release led to the formation of NiTe2 nanoparticles and intergranular fractures within the Bi2Te3 materials. These results indicate that interfacial degradation and subsequent grain delamination are primary causes to micro-TED failure under current shocks. These findings underscore the significance of considering electrical stress in micro-TED design to enhance reliability and performance for high-power applications.

Revealing the electrolyte suitability optimization and failure mechanism of sodium-ion pouch cells with Na3.5V1.5Mn0.5(PO4)3 polyanionic cathode

Polyanionic cathodes are promising for sodium-ion batteries (SIBs) in large-scale energy storage applications, but there is almost no research on the failure mechanisms of SIBs with polyanionic cathodes. Herein, we investigate the failure mechanisms of the pouch cells with the Na3.5V1.5Mn0.5(PO4)3 (NVMP) polyanionic cathode and hard carbon (HC) anode. Firstly, the sodium salts are studied in same electrolyte solvents by combining theoretical calculation and electrochemical tests, and NaClO4 is verified as suitable for NVMP//Na half-cells, while NaPF6 is optimal for the cells containing HC electrode. Secondly, the charging cut-off voltages significantly affect the cycling performance. For the NVMP pouch cells cycled within 1.5 ∼ 4.2 V, slight electrolyte oxidation occurs during the final stage of each charge cycle, leading to macroscopic “swelling” after 500 cycles. Finally, for the NVMP pouch cells cycled >3000 cycles within 1.5 ∼ 4.0 V, the main failure mechanism is the “sodium deficiency” and the irreversible deactivation of manganese ions in the waste NVMP cathode, rather than the oxidation of the spent separator or the “sodium precipitation” on the spent HC anode. This work addresses critical gaps in failure mechanism research and lays a foundation for the large-scale application of SIBs with polyanionic cathodes.

Damage and Crack Propagation Mechanism of Q345 Specimen Based on Peridynamics with Temperature and Bolt Holes

With the increasing demand for the performance and design refinement of steel structures (including houses, bridges, and infrastructure), many structures have adopted ultimate bearing capacity in service. The design service lives of steel building structures are generally more than 50 years, and most of them contain bolted connections, which suffer from extreme conditions such as fire (high temperature) during service. When the structure contains defects or cracks and bolt holes, it is easy to produce stress concentration at the defect location, which leads to crack nucleation and crack propagation, reduces the bearing capacity of the structure, and causes the collapse of the structure and causes disasters. In the process of structural damage and crack propagation, the traditional method has some disadvantages, such as stress singularity, the mesh needing to be redivided, and the crack being restricted to mesh; however, the integral method of peridynamics (PD) can completely avoid these problems. Therefore, in this paper, the constitutive equation of PD in high temperature is derived according to the variation law of steel material properties when changed by temperature increase and peridynamics parameters; the damage and crack expansion characteristics of Q345 steel specimens with bolt holes and a central double-crack at 20 °C, 200 °C, 400 °C, and 600 °C were analyzed to clarify the structural damage and failure mechanism. This study is helpful for providing theoretical support for the design of high-temperature steel structures, improving the stability of the structure, and ensuring the bearing capacity of the structure and the safety of people’s lives and property.

Progressive failure analysis of laminates with an open hole subjected to compressive loading (OHC) using the enhanced semi-discrete modeling framework

The Open-hole compressive (OHC) strength of a fiber reinforced laminate is one of the most critical allowables for design of aerostructures. In this paper, results for predicting the OHC strength using the semi-discrete damage modeling framework are presented. The predictions are seen to capture experimentally observed failure mechanisms and measured failure loads. The constitutive model includes local axial compressive failure (and subsequent load bearing at a reduced plateau stress) while maintaining numerical robustness. Standard stacking sequences (quasi-isotropic, “hard” and “soft”) have been analyzed and compared to publicly available databases. Additionally, the model is challenged to predict delamination-dominated failure due to ply-scaling. Overall, the model is able to capture relevant failure mechanisms, while the ultimate loads are predicted with good accuracy. Therefore, this framework can be used with confidence in predicting OHC strengths of laminates.

A Contact Mechanics Model for Surface Wear Prediction of Parallel-Axis Polymer Gears.

As surface wear is one of the major failure mechanisms in many applications that include polymer gears, lifetime prediction of polymer gears often requires time-consuming and expensive experimental testing. This study introduces a contact mechanics model for the surface wear prediction of polymer gears. The developed model, which is based on an iterative numerical procedure, employs a boundary element method (BEM) in conjunction with Archard's wear equation to predict wear depth on contacting tooth surfaces. The wear coefficients, necessary for the model development, have been determined experimentally for Polyoxymethylene (POM) and Polyvinylidene fluoride (PVDF) polymer gear samples by employing an abrasive wear model by the VDI 2736 guidelines for polymer gear design. To fully describe the complex changes in contact topography as the gears wear, the prediction model employs Winkler's surface formulation used for the computation of the contact pressure distribution and Weber's model for the computation of wear-induced changes in stiffness components as well as the alterations in the load-sharing factors with corresponding effects on the normal load distribution. The developed contact mechanics model has been validated through experimental testing of steel/polymer engagements after an arbitrary number of load cycles. Based on the comparison of the simulated and experimental results, it can be concluded that the developed model can be used to predict the surface wear of polymer gears, therefore reducing the need to perform experimental testing. One of the major benefits of the developed model is the possibility of assessing and visualizing the numerous contact parameters that simultaneously affect the wear behavior, which can be used to determine the wear patterns of contacting tooth surfaces after a certain number of load cycles, i.e., different lifetime stages of polymer gears.

Post-disaster investigations of damage feature of buildings and structures due to several local strong winds in China during 2021–2024

Local strong winds such as tornadoes and downbursts are rare in terms of measured wind speed data due to their rapid formation and strong destructive power. Post-disaster investigations have become an important approach for rating the strength of these two kind of winds and analyzing structural failure mechanism. From 2021 to 2024, several tornadoes and downbursts occurred in China. This study delineated changes in the intensity levels of wind disasters along their paths based on on-site disaster investigations and established standards for the level of structural damage based on the extent of functional loss and repair. This study focused on the damage feature to light steel structures, masonry structures, steel-concrete structures, and pole structures, and discussed the causes of the damage from the perspectives of construction and force transmission mechanisms. In addition, this study estimated the equivalent wind speeds based on the damage feature of pole structures and metal roof claddings. To reproduce the damage process for a group of high-rise buildings, the computational fluid dynamic (CFD) technology is used to simulate the airflow distribution inside buildings under two conditions of open and closed interior doors. The investigation results can provide useful information for the wind intensity classification and rating standards in China. Meanwhile, compared with the interior doors being open or closed, closing indoor doors during strong winds can significantly reduce indoor wind speeds, which is beneficial for ensuring safety.

Effect of torsional angle on the fretting wear behavior and fracture failure mechanism of steel wires with spiral contact structure

The fretting wear of steel wire will reduce the service life of wire rope and severely threaten the safety of mine hoisting. To investigate the influence of torsion on the fretting wear behavior of steel wire, the fretting wear tests of steel wires with spiral contact structure under the action of tensile-torsional coupling forces were conducted, and the fatigue fracture failure mechanism was revealed. The result indicates that the CoF increases with increasing torsional angle. As the cycles increase, the sliding distance between the wires decreases, while the adhesion increases. The fretting area gradually transitions from gross sliding status to partial sliding status. The sliding distance and energy loss between the wires increase with increasing torsional angle. The wear depth and coefficient increase with increasing torsional angle, and the wear level of peak contact structure is more serious than that of valley contact structure. The primary wear mechanisms of steel wire are abrasive wear, adhesive wear and fatigue wear. The fatigue fractograph of steel wire is obviously divided into fatigue source zone, crack growth zone and final fracture zone. Abundant secondary cracks and dimples exist in the final fracture zone, and the fatigue fracture failure mechanism is mainly ductile fracture.

Modeling and failure mechanism study of unidirectional GFRP corrugated sandwich sheet piles based on discrete element method

In this paper, a DEM model of a unidirectional glass fiber reinforced polymer composite sandwich sheet pile (UGFRP-CSSP) is developed to elucidate the damage mechanisms under longitudinal bending and axial compression at the mesoscale, in order to bridge the gap between existing knowledge and its potential applications as sheet pile walls. A series of four-point bending and axial compression tests are performed on UGFRP-CSSP to validate the DEM model, which is calibrated through a sensitivity analysis of the mesoscopic parameters. The failure behavior, crack progress, and initial crack formation of the UGFRP-CSSP are investigated by correlating the results from physical experiments and numerical simulations. The research reveals that the DEM model accurately depicts the failure behavior under bending and compression of unidirectional (UD) composite elements, offering a mesoscopic perspective on the failure origins. It is identified that the tensile shear strength of the resin is the weak point leading to initial failure, as it is lower than that of the glass fibers. Longitudinal bending failure typically initiates at the skin-core interface and around the central axis of core, with cracks propagating longitudinally due to compression shear failure between fibers. Axial compression failure also occurs predominantly at the skin-core interface, with similar longitudinal cracking attributed to tensile shear failure at the acute angle fiber connections in the long span side. Finally, a new viewpoint was proposed that the fiber modulus may have a decisive impact on the failure behavior of UD composite materials.

Numerical simulation of failure and micro-cracking behavior of non-persistent rock joint under direct shear

Persistency, as a key geometric parameter of joints, significantly affects shear strength parameters of jointed rock mass. A good understanding of how persistency affects shear behavior of joint is therefore crucial for better evaluation of stability of rock slope. To investigate the failure and micro-cracking behavior of non-persistent rock joint under direct shear, a novel Voronoi generation algorithm is first used to establish an improved grain-based model (GBM) of granite which considers the shape of feldspar. The calibrated model is then used to simulate the direct shear test of numerical models possessing different joint persistency under various normal stresses. The results reveal that the developed micro-cracks generally increase rapidly when the shear strain reaches to a value approximately 50 % of the peak shear strain and the grain boundary tensile micro-crack is dominant among these initiated micro-cracks. Micro-cracks generally initiate at the ends of rock bridge, and then gradually propagate to the central of rock bridge, forming en-echelon fractures. The failure mode of numerical model is closely related to the generated en-echelon fractures. An increase in both joint persistency and normal stress can lead to a shear failure. The finding in this study provides an important basis for understanding the mechanical behavior and failure mechanism of jointed rock mass.

Fatigue reliability analysis methodology based on fatigue life and failure mechanism for carburized gear

Gears are one of the important components in mechanical products, and their fatigue reliability determines the safety performance of mechanical products. In this paper, the fatigue characteristics of carburized gears under different torque and constant rotational speed conditions are investigated by using a gear contact fatigue testing machine, and combined with the dynamic maximum contact stress distribution on the subsurface of the meshing gears, the very-high cycle fatigue P-S-N curves of carburized gears under a stress ratio of −1 is established. Local stress concentration in the surface or subsurface of carburized gears causes grain dislocation movement under the combined influence of maximum contact and residual stresses, and then causes dislocation pileup and transcrystalline rupture after being hindered by grain boundaries, ultimately leading to pitting and fatigue failure of gears. Based on the dislocation energy method and combined with the fatigue failure mechanism of gears, a life prediction model of gears with good prediction results is established by considering the interaction of factors such as dynamic load, grain size, initial crack length, residual stress, slip band length and width. A fatigue reliability analysis method of gears is established based on the life state equation of gears considering the life prediction model. Further analyses of the influence of rotational speed, grain size, residual stress, slip band width, slip band length and initial crack size on the fatigue life reliability index of the gears resulted in the conclusion that the fatigue reliability of the gears not only decreases with the increase of the above-mentioned parameters, but also shows decreasing trend with the increase of time. This is of significance for evaluating the fatigue reliability of gears under very-high cycle fatigue conditions.

Failure mechanism and crashworthiness optimization of variable stiffness nested origami crash box

In recent years, the study of the crashworthiness of lightweight and efficient thin-walled energy-absorbing structures has received increasing attention. In this work, 3D printing technology was adopted to create a nested origami crash box with stiffness variation, which was made of short carbon fiber reinforced nylon material. The structure effectively inhibits the development of failure behavior of short carbon fiber-reinforced nylon origami crash box due to material brittleness. The quasi-static compression experiment results indicate that compared to origami crash box, nested origami crash box improves by 40% in specific energy absorption and 50% in crash force efficiency, while the initial peak crushing force remains unchanged. The effects of three key geometrical parameters, namely dihedral angle, distance between tubes, and height difference on the damage mechanism of the nested origami crash box are discussed in detail using the finite element method, and the response surface model combined with the non-dominated sorting genetic algorithm II is used for multi-objective optimization. In this work, the concepts of origami theory and nested systems are integrated for the first time, aiming to achieve a stable and efficient energy-absorbing deformation mode by precisely modulating the stress transfer path of the structure and its stiffness. This work provides new ideas for the design and fabrication of novel lightweight energy-absorption boxes.