Stress Analysis Model Research Articles

An Improved Iterative Predictive Model for Grinding Residual Stress Considering Material Microstructure Evolution

Abstract During micro-grinding, multiple abrasive grains on grinding wheel circulate on the workpiece causing alternating mechanical and thermal loads which result in microstructure evolution. The microstructure evolution affects the flow stress of the material, which in turn affects force and temperature. This paper thoroughly investigates the cyclic iterative mechanism and proposes an analytical model to predict micro-grinding-induced residual stress. In this investigation, the flow stress model is developed considering temperature, strain, strain rate, yield stress, and material microstructure evolution, based on which, the micro-grinding force and temperature are calculated. On the basis, the evolution of grain size and phases transformation induced by force and temperature are calculated, in turn affected grinding force by flow stress. Then, the analytical model of residual stress is proposed incorporating the stresses induced by mechanical and thermal loadings as well as microstructure evolution. Moreover, the elastic or plastic deformation is determined according to Von-Mises criterion with the developed plastic modulus model in the stress relaxation process. Finally, the residual stress is measured to validate the improved iterative model. By comparing the traditional models, the results indicated that the developed cyclic iterative model obtains a higher accurate prediction of residua stress.

Strength Analysis and Reinforcement of 120 m3 Liquid Helium Storage Tank for Transportation Case

To ensure the safe transportation of a 120 m3 liquid hel ium storage tank, based on the analysis of its structure, material, and load characteristics, a finite element model for stress and strength analysis is established and solved by using the coupled thermo-mechanical analysis method for the accelerating and cornering cases experienced by the tank during transportation. The stress and deformation distributions in different transportation cases are analyzed in comparison to the finite element model, and the strength check is carried out for the tank. The study shows that under various working cases, the extreme value of stress of some parts is 267.5 MPa; this does not satisfy the strength requirement, and therefore requires structural reinforcement. The analysis of the reinforcing effect of the reinforcement structure shows that the stress extremes of the dangerous parts of the tanks after reinforcement decreased by 63.7% and 34.7%; the structural strength meets the standard requirements, and the new reinforcement structure only leads to an increase of 6% in the liquid nitrogen consumption of the cold screen, which is a better reinforcing effect.

Revisiting the strain rate sensitivity of the flow stress of copper: Theory and experiment

One of the most important issues related to the strength of metals is the strain rate sensitivity of the flow stress. In this study, an analytical model of the flow stress as a function of strain rate is derived theoretically. The model can reproduce the strain rate sensitivity of the flow stress of copper over a wide range of strain rates (up to 109 s−1) quantitatively. Our theoretical derivations indicate that the strain rate sensitivity of the flow stress, especially that above 103 s−1, is a result of both the variation of the dislocation mobility mechanism with stress and the particular stress dependence of dislocation density but is not a result of each single mechanism. In particular, the stress dependence of the dislocation density and the initial dislocation density are critical to the quantitative relation of the flow stress–strain rate at high strain rate and the strain rate threshold, under which the upturn of the flow stress occurs, respectively. Moreover, experiments with copper of different initial dislocation densities at moderate and high strain rate are performed. The strain rate threshold of the flow stress upturn observed in the experiments grows considerably as initial dislocation density increases, which is in accordance with theoretical prediction by our model.

Thermal-mechanical coupling characteristics of large-scale molten salt storage tanks under stable operating conditions with varying liquid levels

The large-scale molten salt storage tank is a critical component of the thermal storage system employed in concentrating solar power (CSP) plants. The storage tank is subjected to complex conditions, including high temperature, fluctuating hydrostatic pressure, and thermal stress. Therefore, it is imperative to investigate the thermal-mechanical coupling characteristics of the tank during stable operation under varying liquid levels to comprehensively understand its behavior. The study commences by establishing thermal and stress analysis models for the tank, laying the foundation for subsequent investigation. Subsequently, a comprehensive thermal-mechanical coupling model is constructed using a sequential coupling approach, enabling a more accurate representation of the system's behavior. Finally, an in-depth study is conducted to explore the thermal-mechanical coupling characteristics of storage tanks at various liquid levels. The results indicate that radiation emitted by high-temperature air, confined in the top space of the tank, induces a temperature differential of approximately 5 °C between the tank's roof and the molten salt confined within it. Furthermore, heat loss from the roof accounts for 53 % of the overall heat loss. Thermal stress analysis of each weld seam connecting the tank into an integration reveals that the inner surface experiences tensile stress, while the outer surface undergoes compressive stress, primarily influenced by radial stress. Under the influence of thermal-mechanical, the coupling effect leads to compressive stress in the form of thermal stress, resulting in a decreasing trend in stress on the inner surface of the weld seam. The radial compressive stress on the outer surface reaches approximately 140 MPa, while the tank wall is primarily subjected to circumferential forces. The temperature exerts a negligible impact on the stress of the tank wall, yet it significantly affects its deformation. The stress evaluation of hydrostatic pressure and thermodynamic coupling under different liquid levels is carried out, and the results meet the strength requirements.

Optimization of structural reinforcement assessment for architectural heritage digital twins based on LiDAR and multi-source remote sensing

This study investigates the geometric modelling of architectural heritage digital twins constructed based on multi-source point cloud data and its effectiveness in structural reinforcement assessment. Particular emphasis has been placed on the use of static stiffness rules to identify areas of structural weakness in the geometric models of digital twins and the need for their reinforcement, in order to prevent potential structural problems and to ensure the long-term preservation of the built heritage. Taking Yingxian wooden pagoda as a study case, based on the collection of multi-source point cloud data, the digital twin geometric model is constructed through fine modelling, decoupling of digital models, and geometric transformation. This enhances the true reflection of the column-architrave structure morphology, providing a more accurate model for structural stress analysis. Based on verifying the accuracy of the digital twin geometric model, the instability conditions are identified through static stiffness rules and the deformation values at multiple points are analyzed, enabling precise identification of weak areas in the column-architrave structure. Two types of reinforcement measures are designed and simulated for the structural weak areas identified through the geometric modelling, and the optimal reinforcement scheme is obtained after detailed analysis, according to which specific adjustments and optimization strategies are proposed to enhance the overall stability and durability of the structure. The results showed that the maximum deformation value of 4.65 mm existed in column M2W23, which required reinforcement. Aluminum reinforcement reduced the deformation to 3.5 mm (24.7% reduction), while CFRP fabric reinforcement was more effective, reducing the deformation to 2.8 mm (39.7% reduction), showing high stability. The research results demonstrate the potential application of digital twin technology in architectural heritage preservation and restoration, providing methodological and empirical guidance for heritage preservation research.

Nonlinear seismic response analysis of liquefiable sites based on effective stress method

In this study, the one-dimensional nonlinear Matasovic model was extended to the two- and three- dimensional stress space by replacing the shear strain with the generalized shear strain. The extended Matasovic model was subsequently combined with Dobry’s excess pore water pressure generation model, and the reliability of the proposed loosely coupled effective stress analysis model was verified through undrained cyclic triaxial tests and a one-dimensional site response analysis. Finally, this method was applied to an engineering site in China to evaluate the nonlinear seismic response of liquefiable sites. The results show that the proposed effective stress analysis method can capture the dynamic behavior of the soil and the generation of pore water pressure during strong shaking. Moreover, there are differences between the proposed effective stress analysis method and the total stress analysis method for liquefiable sites, which indicates the need for careful selection in practical applications.

Analytical modelling for residual stress prediction in multi-step side milling of GH4169 thin-wall parts based on deformation

GH4169 thin-walled parts are widely used in aerospace due to their high-temperature, corrosion resistance, and fatigue strength. However, they often deform from machining-induced residual stress, which is a significant unresolved manufacturing challenge. Additionally, initial residual stress from previous steps critically impacts subsequent processes. This study found that the residual stress of side milling of thin-walled parts under smaller cutting parameters is mainly caused by mechanical effects, and the influence of milling heat can be ignored. In this study, an analytical prediction model for residual stress of multi-step side milling thin-walled parts based on the deformation of thin-walled parts is proposed for the first time, which is suitable for smaller cutting parameters. Then, the proposed model is examined the mechanisms through which residual stresses develop during side milling and defined the applicability of model based on specific assumptions. To validate these assumptions, an experimental setup was devloped to simulate the movement of the heat source during milling. Subsequent two-step side milling experiments on GH4169 confirmed the accuracy of the analytical prediction model in predicting the residual stresses of multi-step side milling in thin-walled parts. It was observed that higher equivalent bending stiffness in thin-walled parts correlates with reduced machining deformation. The analytical model also provides a strategic approach to control machining deformation by managing the equivalent bending stiffness of the parts.

Development of Low-Pressure Die-Cast Al-Zn-Mg-Cu Alloy Propellers Part II: Simulations for Process Optimization.

With the increasing demand for high-performance leisure boat propellers, this study explores the development of high-strength aluminum alloy propellers using the low-pressure die-casting (LPDC) process. In Part I of the study, we identified the optimal alloy compositions for Al-6Zn-2Mg-1.5Cu propellers and highlighted the challenges of hot tearing at the junction between the hub and blades. In this continuation, we developed a coupled thermal fluid stress analysis model using ProCAST software to optimize the LPDC process. By adjusting casting parameters such as the melt supply temperature, initial mold temperature, and curvature radius between the hub and blades, we minimized hot tearing and other casting defects. The results were validated through simulations and practical applications, showing significant improvements in the quality and structural integrity of the propellers. Non-destructive testing using X-ray CT confirmed the reduction in internal defects, demonstrating the effectiveness of the simulation-based approach for alloy design and process optimization.

Assessment of failure modes of a rising stem type gate valve according to ASME BPVC Section-VIII, Division-2 criteria

Assessing the structural integrity of valves is crucial during the development process. Design by analysis involves evaluating unconventional geometries and loads by researching and classifying stresses, then comparing them to allowable values. Although ASME BPVC Section-VIII, Division-2 does not specifically cover valves, key valve design standards reference this code. Hence, this numerical study aims to develop and apply specialized stress analysis models for evaluating plastic collapse and local failure in a rising stem-type gate valve. The methodology is developed to assess the elastic behavior of the valve under stress to evaluate plastic collapse. It is also designed to assess plastic collapse and local failure by considering the material’s behavior beyond the elastic range and into the plastic deformation zone. A numerical model using the ANSYS–MECHANICAL tool was developed based on the finite element technique. The main failure modes of a rising stem-type gate valve according to ASME BPVC Section-VIII, Division-2 criteria were considered. The main contribution to valve development is providing specialized stress analysis models and numerical simulations, mainly focusing on the rising stem-type gate valve and aligning it with relevant ASME standards. The results showed that the maximum von Mises stress in the valve body was 200.6 MPa, staying below the yield limit, while the screws surpassed the yield limit with 725.72 MPa, entering the plastic deformation zone.

Aeronautical composite/metal bolted joint and its mechanical properties: a review

PurposeBolted joint is the most important connection method in aircraft composite/metal stacked connections due to its large load transfer capacity and high manufacturing reliability. Aircraft components are subjected to complex hybrid variable loads during service, and the mechanical properties of composite/metal bolted joint directly affect the overall safety of aircraft structures. Research on composite/metal bolted joint and their mechanical properties has also become a topic of general interests. This article reviews the current research status of aeronautical composite/metal bolted joint and its mechanical properties and looks forward to future research directions.Design/methodology/approachThis article reviews the research progress on static strength failure and fatigue failure of composite/metal bolted joint, focusing on exploring failure analysis and prediction methods from the perspective of the theoretical models. At the same time, the influence and correlation mechanism of hole-making quality and assembly accuracy on the mechanical properties of their connections are summarized from the hole-making processes and damage of composite/metal stacked structures.FindingsThe progressive damage analysis method can accurately analyze and predict the static strength failure of composite/metal stacked bolted joint structures by establishing a stress analysis model combined with composite material performance degradation schemes and failure criteria. The use of mature metal material fatigue cumulative damage models and composite material fatigue progressive damage analysis methods can effectively predict the fatigue of composite/metal bolted joints. The geometric errors such as aperture accuracy and holes perpendicularity have the most significant impact on the connection performance, and their mechanical responses mainly include ultimate strength, bearing stiffness, secondary bending effect and fatigue life.Research limitations/implicationsCurrent research on the theoretical prediction of the mechanical properties of composite/metal bolted joints is mainly based on ideal fits with no gaps or uniform gaps in the thickness direction, without considering the hole shape characteristics generated by stacked drilling. At the same time, the service performance evaluation of composite/metal stacked bolted joints structures is currently limited to static strength and fatigue failure tests of the sample-level components and needs to be improved and verified in higher complexity structures. At the same time, it also needs to be extended to the mechanical performance research under more complex forms of the external loads in more environments.Originality/valueThe mechanical performance of the connection structure directly affects the overall structural safety of the aircraft. Many scholars actively explore the theoretical prediction methods for static strength and fatigue failure of composite/metal bolted joints as well as the impact of hole-making accuracy on their mechanical properties. This article provides an original overview of the current research status of aeronautical composite/metal bolted joint and its mechanical properties, with a focus on exploring the failure analysis and prediction methods from the perspective of theoretical models for static strength and fatigue failure of composite/metal bolt joints and looks forward to future research directions.

Dynamic stress response in reservoirs stimulated by fluctuating fluid pressure during pulsating hydraulic fracturing

Determining the most effective scheme for fracturing operations depends on accurate calculations of reservoir stress. Traditional fracturing theories usually focus on stable fluid injection modes, which employ static assumptions in modelling and analysis. However, pulsating hydraulic fracturing (PHF) introduces fluctuating fluid pressure to stimulate reservoirs, which requires considering dynamic factors and exploring the dynamic stress response within the reservoir. Furthermore, reservoirs are often classified as homogeneous continuous or porous media materials, but the boundaries between these classifications are sometimes apparent. This paper investigated the development of both an elastodynamics model and a poroelastodynamics model for calculating dynamic stress responses during PHF. The staggered grid finite difference method addressed these models, with the outer boundary employing the perfectly matched layer (PML) method to simulate an infinite reservoir. The numerical simulation results were extensively verified and compared with analytical solutions, and the differences between various models and their relevant conditions were thoroughly analyzed. Analyzing fluid pressure fluctuation parameters revealed noteworthy insights into reservoir stress response characteristics. Results indicate that as the Biot coefficient and permeability increase, the disparities between the elastodynamics and poroelastodynamics models become prominent. In practical terms, high Biot coefficient or high permeability reservoirs necessitate using the poroelastodynamics model for accurate reservoir stress analysis. As the frequency of fluid pressure fluctuation increases, the amplitude of response of reservoir circumferential stress also increases, while the response amplitude of radial stress and fluid pressure decreases. These findings offer valuable theoretical guidance for parameter design in engineering applications during PHF.

Research on Multi-Directional Spalling Evolution Analysis Method for Angular Ball Bearing

The prediction of spalling failure evolution in the lifespan of aeroengine bearings is crucial for en-suring the safe return of aircrafts after such failures occur. This study examines the spalling failure evolution process in bearings by integrating the proposed spalling region contact stress analysis model with the multi-directional subsurface crack extension analysis model. The results elucidate the general pattern of spalling expansion. Utilizing this methodology, the fatigue spalling fault evolution in bearings is thoroughly analyzed. Additionally, a two-dimensional model has been developed to simulate and analyze crack propagation in the critical direction of the spalling region, significantly enhancing the model’s computational efficiency.

Failure characteristics and fracture mechanism of overburden rock induced by mining: A case study in China

This study employs similar simulation testing and discrete element simulation coupling to analyze the failure and deformation processes of a model coal seam's roof. The caving area of the overburden rock is divided into three zones: the delamination fracture zone, broken fracture zone, and compaction zone. The caving and fracture zones' heights are approximately 110 m above the coal seam, with a maximum subsidence of 11 m. The delamination fracture zone's porosity range is between 0.2 and 0.3, while the remainder of the roof predominantly exhibits a porosity of less than 0.1. In addition, the numerical model's stress analysis revealed that the overburden rock's displacement zone forms an 'arch-beam' structure starting from 160 m, with the maximum and minimum stress values decreasing as the distance of advancement increases. In the stress beam interval of the overburden rock, the maximum value changes periodically as the advancement distance increases. Based on a comparative analysis between observable data from on-site work and numerical simulation results, the stress data from the numerical simulation are essentially consistent with the actual results detected on-site, indicating the validity of the numerical simulation results.

General Analytical Model and Experimental Verification for Mechanical Stress of High-Speed Interior Permanent Magnet Motors Considering Modified Rotor

General Analytical Model and Experimental Verification for Mechanical Stress of High-Speed Interior Permanent Magnet Motors Considering Modified Rotor

Analysis of dynamic thermal behaviors for multi-stage hydraulic fracturing treatments in horizontal shale oil and shale gas wells

Accurate prediction of dynamic thermal behaviors during multi-stage hydraulic fracturing is profound which can avoid performance deterioration of fracturing fluids or failure of fracturing tools caused by severe temperature variation. This paper establishes a transient heat transfer model for multi-stage hydraulic fracturing in horizontal shale oil and shale gas wells (MFHWM), considering the real construction process of multi-stage hydraulic fracturing, the turbulent flow state, the heat source of viscous dissipation and the complex wellbore structure, which enables the accurate simulation of thermal behaviors in the early time of multi-stage hydraulic fracturing with large flow rate. The verification results of measured temperature data and simulation data prove the MFHWM has good precision. Numerical simulations indicate that the temperature distribution exhibits the characteristics of cyclic “cool-down” and “warm-back” and “stair-step” during the multi-stage hydraulic fracturing. In the “cool-down” period, the temperature drops sharply within the first hour and then the deceleration slows down. In the “warm-back” period, the temperature recovers exponentially relying on the shut-in time. The “stair-step” is caused by changing of heat transfer mechanism from convection to conduction. Moreover, the cyclic cooling has little effect on the total temperature drop and subsequent stages are not significantly cooler than previous stages. Besides, primary factors affecting temperature distributions of wellbore-formation system are discussed thoroughly. Results indicate that the viscous heat source cannot be ignored for multi-stage hydraulic fracturing and the temperature difference exhibits cyclic variation when considering and without considering the viscous heat source. In addition, the minimum temperature during each-stage-fracturing operation decreases first and then increases as the injection rate of fracturing fluid increases because of the compromise between the viscous heat source and forced convection. Furthermore, temperature distributions can be controlled by changing the injection temperature of fracturing fluid. As the injection temperature increases, a positive proportional relationship exists between the minimum temperature of fracturing fluid and the injection temperature. MFHWM can be a standalone tool to analyze temperature distributions of multi-stage hydraulic fracturing. It can also be used to provide better boundary conditions for stress analysis model of casing and cement sheath.

Experimental Study on Tensile Performance of FRP Tendons/Cables with Varied Bond Anchorage Factors.

FRP tendons and cables are increasingly being used in civil engineering structures due to their high strength-to-weight ratio and corrosion resistance. The bond anchorage factors, which characterize the bond strength between the FRP tendon/cable and the surrounding materials, play a critical role in determining the overall performance of the system. In this study, a series of tensile tests were conducted on FRP tendons/cables with different bond anchorage factors to evaluate their load-carrying capacity, load-displacement curve, and strain distribution. The study considered different types and surface shapes of FRP tendons/cables, and determined the influence of anchoring length, bonding medium type, and bonding medium thickness on the performance. The strain distribution of FRP tendons/cables at the anchorage end gradually increased along the loading section to the free end. A stress analysis model of the anchoring section was proposed and found to be consistent with the test results.

Millet yield estimations in Senegal: Unveiling the power of regional water stress analysis and advanced predictive modeling

Crop yield is usually affected by impending weather, climate conditions, and human interventions like irrigation. Hence, the prompt detection of regions experiencing water scarcity can aid in implementing effective mitigation strategies. Our study utilized a data-driven approach to compute a Water Demand Index (WDI), which incorporates crucial first-order geophysical variables like ambient temperature, vegetation status, and soil moisture, to identify water-stressed fields in Senegal’s agricultural regions during the millet planting, growing, and harvesting periods. We have also explored various scenarios for enhancing the accuracy of millet yield prediction by incorporating other drought indices, soil characteristics, and a bias correction factor. The novel aspects of this research include the development of regional crop yield predictive models based on sub-seasonal and unaggregated crop information to reflect local variances. To optimize the hyperparameters of machine learning (ML) models, various techniques were utilized. Meanwhile, the performance of these ML models was evaluated using a nested cross-validation approach. The outcomes of the analysis demonstrate that the Random Forest Regressor model exhibits superior predictive performance. The results imply that a holistic approach, encompassing diverse environmental factors and crop growth stages, could result in more precise and dependable millet yield predictions. These results mark a leap forward in crop yield prediction for data-poor regions, paving the way for more accurate and efficient agricultural management. By emphasizing the critical role of detailed, spatio-temporal data, this work substantially enhances model precision, informing targeted strategies to boost yields. This advancement stands to serve producers and consumers alike, fostering sustainable, high-yield agriculture.

Three-dimensional analytical model for residual stress in the weld of thick plates by friction stir welding

Three-dimensional analytical model for residual stress in the weld of thick plates by friction stir welding

Calculation and Analysis of Motor Thermal Stress With or Without Eccentricity for In-Wheel Electric Vehicle Applications

The requirement of high-power density and the problems of high temperature and uneven air gap caused by environmental constraints make the alternating effect of internal temperature and related constraints between components during the operation of the motor for in-wheel electric vehicle. These effects and constraints will lead to thermal stress and concomitant deformation, and seriously affect the safe operation of in-wheel motors (IWMs) and vehicles. Aiming at the above problems, this paper takes a 15kW IWM as the research object. Based on the analysis of the mutual coupling relationship between the multi-physics field, such as the electromagnetic field, the temperature field, the flow field and the structural field, a thermal stress analysis model of the IWM is established and verified firstly. Then, quantitative calculation of the thermal stress/strain state of the IWM with or without eccentricity is carried out under different working conditions. The analytical results show that the thermal load generated internally leads to the generation of uneven thermal stress and accompanying thermal deformation, and the maximum thermal stress (MTS) and maximum thermal deformation (MTD) do not appear on the same component. Although eccentricity does not affect the position of the MTS and the MTD, it has an important effect on the maximum value of the stress and deformation, especially the eccentricity exceeds 30%. The results also demonstrate that the permanent magnet (PM) is most significantly affected by the eccentricity.

Interfacial stresses of beams hybrid strengthened by steel plate with outside taper and FRP pocket

This study proposes a new hybrid strengthening method, for which the reinforced concrete (RC) beams are strengthened in flexure by externally bonding a steel plate with variable thickness and an FRP pocket with end-anchorage. To investigate the influence of the stress distribution along the bondline on the strengthening effect, this paper develops an interfacial stress analysis model for RC beams strengthened with the proposed method under arbitrary loads. Based on the assumptions of linear elasticity, deformation coordination and static equilibrium conditions, the expressions of normal and shear stresses at the steel-concrete and FRP-steel interfaces of the strengthened RC beams under different loads and boundary conditions are derived. Finally, four-point bending tests on RC beams strengthened in flexure by using the proposed method were carried out. The steel plate with a fillet is beneficial to prevent the end debonding since it can significantly reduce the interfacial stresses at the end of the steel plate. Also, the results show good agreement between the calculated and tested results, which verified the applicability of the proposed model.