Shear Friction Research Articles

Enhancing Shear Strength in Hybrid Metal-Composite Single-Lap Joints Using Z-pins Fabricated via Fused Filament Fabrication

This paper investigates the interfacial shear strength of hybrid metal-composite single-lap joints (SLJs) reinforced with stainless steel Z-pins fabricated by fused filament fabrication (FFF). The joints were created by 3D printing an orthogonal array of 2 mm diameter steel Z-pins onto a steel substrate using FFF. The Z-pins were then embedded into a basalt fibre (BF)-fabric/epoxy resin composite using the Ultrasonically Assisted Z-FibreTM (UAZ) method to form a high-strength and tough interface. The results demonstrate that steel Z-pins produced via FFF effectively enhance the shear strength of the hybrid metal-composite SLJs, significantly improving joint performance. The study also explores the influence of Z-pin volume fraction and embedding height on SLJ shear strength. It was found that higher volume fractions and greater embedding heights of the Z-pins contribute to the increased shear strength. Compared to unreinforced joints, the maximum shear strength of the steel Z-pin reinforced joints increased by 120.1%. This enhancement is attributed to the effective energy absorption mechanisms, primarily facilitated by the frictional pull-out, plastic deformation and shear fracture of Z-pins accompanied by the formation of ductile dimples. These mechanisms suppress crack propagation and improve joint integrity. This study presents an innovative approach for fabricating hybrid metal-composite joints with enhanced toughness and strength.

Tribological and mechanical endowments of polyoxymethylene by liquid‐phase exfoliated graphene nanofiller

AbstractIn this study, a viable route to the development of a high‐performance polyoxymethylene (POM)‐based nanocomposite is proposed to overcome tribomechanical‐related issues in high‐precision sliding parts. Prior to melt‐blending, graphene nanoplatelet (GNP) filler was processed via a series of liquid‐phase exfoliation and surface modification with 3‐aminopropyltriethoxysilane. Results indicate that GNP is successfully exfoliated with minimum defect ratio and improves interfacial bonding within the matrix. Uniform dispersion and stable load‐transfer capability of POM/GNP with 0.5 wt% loading significantly enhanced flexural, tensile and impact strength by overall 26.4%, in contrast to unfilled POM. Dry friction tests against a steel ball also showed the lowest reduction in friction coefficient and wear rate by 22% and 40.6%, respectively, at the same amount of GNP loading due to the large specific surface coverage and lubricious transfer film chelation onto the steel counterface. Furthermore, dissipated energy accumulation by friction work was calculated in the sliding interfaces based on friction force–displacement hysteresis loop where the POM/GNP 0.5 wt% wear surface consumed ca 21.7% less energy in a dry frictional shearing process compared to neat POM. However, lack or excess loading of processed GNP exhibited insufficient or poor matrix–filler adhesion and led to deterioration of the composite properties due to particle agglomeration which can cause stress concentration and serve as a failure site. The adoption of the proposed methodology would demonstrate excellent material characteristics in thin‐walled precision parts where both mechanical and tribological performances are the primary concern. © 2024 Society of Chemical Industry.

Comparative study of a femoral amputated limb with and without implant

The contact pressure at the socket–residual limb interface is the most critical parameter for evaluating the comfort of a leg prosthesis. Experimental studies have analyzed this parameter for typical postures and during walking on a flat surface of an amputee; however, experimental tests require a real socket prototype equipped with transducers. To optimize socket design, this work presents a virtual approach based on a digital avatar of a patient wearing a lower limb prosthesis. Our study integrates two different types of simulations: the first concerns the femur with an implant, the second without an implant, and includes the evaluation of pressure at the socket–residual limb interface using finite element analyses (FEA). The objective of this study is to understand the distribution of loads and stresses at the interface between the residual limb and the prosthesis. The lower contact pressure is represented by CPRESS, while CSHEAR1 is the frictional shear stress component in the first local tangent direction, and CSHEAR2 is the frictional shear stress component in the second local tangent direction.

Designing High-Sensitivity Mechanochromic Luminescent Materials Through Friction-Induced Crystallization Strategy.

Despite recent significant breakthroughs in novel mechanochromic luminescent (ML) materials, developing a high-sensitivity ML material is still challengeable. Herein, a "friction-induced crystallization" strategy is proposed to realize highly sensitive transformations of luminescent signal, through an integration of polymeric chains and an aggregation-sensitive luminescent core, which act as mechanical sensors and fluochromic actuators, respectively. The coupling of these two components enables the material to crystallize in response to shear friction, thereby exhibiting blue-shift fluorescence due to a more restricted relaxation pathway. This study underscores a high-sensitivity ML material based on the precise regulation of molecular-scale motions, and also expands the scope and potential of ML materials toward user-friendly, interactive wearable devices.

Decoding roughness perception in distributed haptic devices

Abstract The ability to render realistic texture perception using haptic devices has been consistently challenging. A key component of texture perception is roughness. When we touch surfaces, mechanoreceptors present under the skin are activated and the information is processed by the nervous system, enabling perception of roughness/smoothness. Several distributed haptic devices capable of producing localized skin stretch have been developed with the aim of rendering realistic roughness perception; however, current state-of-the-art devices rely on device fabrication and psychophysical experimentation to determine whether a device configuration will perform as desired. Predictive models can elucidate physical mechanisms, providing insight and a more effective design iteration process. Since existing models (1, 2) are derived from responses to normal stimuli only, they cannot predict the performance of laterally actuated devices which rely on frictional shear forces to produce localized skin stretch. They are also unable to predict the augmentation of roughness perception when the actuators are spatially dispersed across the contact patch or actuated with a relative phase difference (3). In this study, we have developed a model that can predict the perceived roughness for arbitrary external stimuli and validated it against psychophysical experimental results from different haptic devices reported in literature. The model elucidates two key mechanisms: 1) The variation in the change of strain across the contact patch can predict roughness perception with strong correlation 2) The inclusion of lateral shear forces is essential to correctly predict roughness perception. Using the model can accelerate device optimization by obviating the reliance on trial-and-error approaches.

Simulation of Friction Stir Welding of AZ31 Mg Alloys.

Friction stir welding has been extensively applied for the high-quality bonding of Mg alloys. The welding temperature caused by friction and plastic deformation is essential for determining the joint characteristics, especially the residual stress and weld microstructure. In this work, a modified moving heat source model was proposed by considering the variations in heat generation caused by friction shear stress at both the side and bottom surfaces of the tool. The application of this model was further extended to the entire welding process, especially in the plunging stage. The relative errors between the experimental and simulated peak temperatures at characteristic points were small, with a maximum of 10%, thereby validating the model for accurate temperature prediction. Furthermore, the influence of welding and rotational speed on temperature fields was systematically investigated. At relatively low welding and rotational speeds, the welding temperature increased significantly with either an increase in rotational speed or a decrease in welding speed. However, this effect gradually diminished at higher welding and rotational speeds. These results provide some valuable guidelines for controlling heat generation to improve the quality of Mg alloy welds.

Identification of coulomb and constant shear frictions in hot aluminum forming by using warm and hot upsetting sliding test

Identification of coulomb and constant shear frictions in hot aluminum forming by using warm and hot upsetting sliding test

Surface-engineered caterpillar-like silica nanocomposites for enhanced interparticle friction and interlock in shear thickening suspension

This study presents a novel method for fabricating surface-engineered caterpillar-like silica nanocomposites by combining rod-like nanorods with spherical nanoparticles to control aspect ratios and surface functionalization. This unique design facilitates functional assembly at the nanoscale. Additionally, we developed an innovative composite by encapsulating polyurethane elastomers within shear thickening fluid (STF)-impregnated Kevlar, significantly enhancing the flexibility and durability of the resulting STF/Kevlar/PU composite. Microstructural and chemical modifications were characterized, and detailed rheological analysis revealed a 165 % increase in viscosity and a substantial rise in storage modulus from 91.56 to 18,640 Pa, indicating improved surface morphology and roughness. These enhancements promoted stronger interparticle friction and rotational motion during flow. Impact resistance tests further demonstrated a 314 % increase in peak impact force, driven by frictional interactions between the dispersed caterpillar-like particles. The results confirmed that surface roughness and adhesive forces play a critical role in activating stress-dependent frictional contacts, a key mechanism behind the improved performance. These findings highlight the potential of these composites for mitigating penetration injuries and offer precise control over the shear-thickening transition in engineering applications, making them promising candidates for lightweight protective materials.

TiO2-hBN nanocomposite coating with excellent wear and corrosion resistance on Ti6Al4V alloy prepared by plasma electrolytic oxidation

Hexagonal boron nitride (hBN) is recognized for its promising application prospects in anti-friction and corrosion resistance due to its self-lubrication and excellent impermeability to gases and liquids. In this study, the TiO2-hBN nanocomposite coatings are prepared via the liquid plasma-assisted particle deposition sintering (LPDS) technology, enabling compact and uniform growth of hBN on the Ti6Al4V surface. Results indicate that the dense and stable plasma at the coating/electrolyte interface facilitates the deposition and sintering of hBN particles, effectively filling surface defects and achieving a coating density of 86.7 %. The friction coefficient of the TiO2-hBN nanocomposite coating significantly decreases from 0.54 (titanium alloy) to 0.28, remaining stable even after 2000 sliding cycles. Compared to the substrate, the wear rate (4.3 × 10−4 mm3N−1 m−1) of nanocomposite coating drops by 70.8 %, which is primarily attributed to the self-lubricating property of hBN, reducing the frictional shear stress. Moreover, the TiO2-hBN nanocomposite coating also has excellent corrosion resistance due to the hBN sheet filling internal defects and inhibiting the corrosion reaction. All these merits render the LPDS technology competitive in expanding the severe service conditions of titanium alloys in aerospace and marine engineering equipment.

Shear capacity prediction of carbon-fibre-reinforced polymer mesh fabric (CFRP-MF) stirrups reinforced concrete beams

Fibre-reinforced polymer mesh fabric (FRP-MF) is an effective substitute for normal steel stirrups in concrete to prevent steel corrosion in reinforced concrete (RC) structures. Nevertheless, methods for calculating the shear resistance of RC members rehabilitated in shear with FRP-MF configurations are lacking. Moreover, the methods for quantitative analysis of the shear contribution caused by the cracking control effect produced by CFRP-MF longitudinal FRP strips are unclear. In this paper, a mechanics-based segmental model is presented based on partial interaction analysis considering both transverse FRP strips and longitudinal reinforcements. By incorporating the carbon-fibre-reinforced polymer mesh fabric (CFRP-MF) stirrups into this model, a shear strength model was proposed and extended for design purposes in a closed form. In addition, the modified compression field theory (MCFT) model considering the shear strength of concrete in compression and the shear friction model (SFM) in the literature were appropriately modified and used for comparison with the segmental model. It should be noted that if the tensile strength of the longitudinal strips was added into the corresponding calculation formulas, it would cause the difference between the proposed novel models with the previous models. Finally, the shear strength of 14 CFRP-MF reinforced concrete beams were evaluated using these three models. The average ratios of the experimental values of the CFRP-MF RC beams to the shear capacity predicted by the modified segmental model, MCFT with the shear contribution of compressed concrete and SFM were 1.30, 1.19 and 1.19, respectively. It turns out that the modified mechanics-based segmental model yields the minimum discreteness based on the experiment results. This study can provide shear capacity calculation and design reference of RC beams with longitudinal FRP strip reinforcements for researchers and engineers.

INVESTIGATION OF THE SHEAR STRENGTH OF REINFORCED SILTY SAND

Introduction: This paper presents an experimental investigation that aims to study the influence of silt content, glass fiber content, and their combined effect on the shear behavior of silty sand. For this purpose, a series of tests using direct shear apparatus (as methods) were carried out on sand mixed with various silt and fiber contents. Samples were prepared with a relative density of 50 %, and each mixture was tested at three different normal stresses. The experimental results indicated an increase in shear strength at 10 % silt content, followed by a decrease in shear strength with increasing silt content from 10 % to 30 %. It was also found that 0.5 % is the optimal content that can be added to sand-silt mixtures to enhance their shear strength and friction angle, although the mixtures become more contractive.

Frictional pull-out work capacity of macro-SSF in concrete composites and evaluation of matrix deterioration due to kinematic fiber-end-slip after full-debonding point

ABSTRACT This paper presents a parametric study on the effect of frictional pull-out work capacity on the performance of fiber/matrix regime during the kinematic pull-out process. This study involves an experimental program of pull-out test of straight steel fiber embedded in concrete composites, numerical study based on finite element modeling, and theoretical approaches based on mathematical model. Various parameters were considered such as fiber geometry, Poisson’s ratio, elasticity modulus, and aspect ratio. The experimental results were calibrated with the results of numerical study, and the theoretical approaches were controlled using deterioration coefficient based on a given curve of uniaxial stress–displacement relationship plotted experimentally. The results showed that the capacity of pull-out work decreases 62.6% when the fiber diameter decreases 6 times. Decreasing the fiber diameter also improves the resistance of the matrix against deterioration. While decreasing the fiber embedded length by 1.8 times, the frictional pull-out work decreases by 56.3% and boosts relatively the resistance of matrix against crumbling, where the frictional shear bond strength improved by 91%. Likewise, decreasing the fiber aspect ratio by 1.8 times decreases the done frictional pull-out work by 56.3% and boosts the fiber duct resistance against damage by improving the frictional shear bond strength.

Environmentally Acceptable Lubricants for Stern Tube Application: Shear Stability and Friction Factor

Stern tube lubricants are essential in maritime operations, safeguarding ship propeller shafts from wear and corrosion while ensuring efficient propulsion. Their role in reducing friction and maintaining system integrity is critical. With growing environmental concerns, the adoption of environmentally acceptable lubricants (EALs) for stern tubes has gained importance, balancing operational performance with environmental protection. This study investigates the rheological and tribological properties of EALs formulated for ship propeller stern tube applications. The primary focus is on comparing these EALs with conventional mineral oils to assess their suitability in marine environments. EALs are increasingly favored due to their biodegradability and reduced environmental impact. Key parameters such as shear stability, friction factor, and temperature dependency were evaluated using a range of experimental methods including rotational viscometry and tribological analysis. The results indicate that the newly formulated EALs based on synthetic esters exhibit the highest viscosity index, a higher range of shear stability, and lower friction factors, compared to commercially available mineral oils, especially under varying operational conditions. These findings contribute to the ongoing efforts to promote eco-friendly lubricants in maritime industries, aligning with global environmental protection initiatives.

Enhancement of Shear Strength Properties of Soft Clay Using Coir Fiber-Coconut Husk Ash-Wood Ash Mixture

Soft clay is a problematic type of soil because it has high water content, low shear strength, low bearing capacity, and high compressibility. This study explores the effectiveness of stabilizing soft clay using a combination of coir fiber, coconut husk ash, and wood ash. This research investigated the impact of incorporating 0.75% coir fiber and varying levels of a coconut husk ash-wood ash mixture (ranging from 0% to 10%) on the shear strength properties of soft clay. The study applied two different curing times: seven and 21 days. An unconsolidated-undrained triaxial test was conducted following ASTM D2850-03. The results demonstrated that combining coir fiber reinforcement with chemical stabilization through the ash mixture significantly enhanced the deviatoric stress, cohesion, internal friction angle, shear strength, and elastic modulus of soft soil. Specifically, an 8% ash content with a 21-day curing time achieved the highest deviatoric stress and shear strength. This highest shear strength value was 210% greater than soil solely reinforced with coir fiber.

Electromagnetohydrodynamic flow and thermal performance in a rotating rough surface microchannel

Rough surfaces in microchannels effectively enhance liquid mixing, thermal performance, and chemical reactions in electrically actuated microfluidic devices. Rotation of the microchannel with surface roughness intensifies this enhancement. We investigate the combined effects of electromagnetohydrodynamics and surface roughness on transient rotating flow in microchannels. We present a mathematical model considering the variable zeta potential, heat transfer characteristics, and entropy generation within the microchannel. We obtain analytical solutions using the separation of variables method and Fourier series expansion. The surface roughness of the microchannel, when combined with rotation, impacts the temperature enhancement. Higher rotation rates result in the formation of multiple vortices. The secondary flow pushes the primary velocity toward the boundary layer, which affects the flow pattern. Surface roughness and electroosmotic flow significantly affect secondary flow, resulting in complex flow patterns and reversals. The interaction between centrifugal and viscous forces results in maximum velocities at the boundary layers. Higher roughness and electromagnetic effects enhance temperature by intensifying fluid-solid friction and joule heating. Surface roughness causes an increase in wall shear stress and friction factor, resulting in a higher Poiseuille number. Moreover, surface roughness increases entropy production by enhancing fluid mixing and internal friction despite improved heat transfer. Higher rotation also elevates entropy generation due to additional vortices induced by secondary flow.

Spines and Inclines: Bioinspired Spines on an Insect-Scale Robot Facilitate Locomotion on Rough and Inclined Terrain.

To navigate complex terrains, insects use diverse tarsal structures (adhesive pads, claws, spines) to reliably attach to and locomote across substrates. This includes surfaces of variable roughness and inclination, which often require reliable transitions from ambulatory to scansorial locomotion. Using bioinspired physical models as a means for comparative research, our study specifically focused on the diversity of tarsal spines, which facilitate locomotion via frictional engagement and shear force generation. For spine designs, we took inspiration from ground beetles (Family Carabidae), which is a largely terrestrial group known for their quick locomotion. Evaluating four different species, we found that the hind legs host linear rows of rigid spines along the entire tarsus. By taking morphometric measurements of the spines, we highlighted parameters of interest (e.g., spine angle and aspect ratio) in order to test their relationship to shear forces sustained during terrain interactions. We systematically evaluated these parameters using spines cut from stainless steel shim attached to a small acrylic sled loaded with various weights. The sled was placed on 3D-printed models of rough terrain, randomly generated using fractal Brownian motion, while a motorized pulley system applied force to the spines. A force sensor measured the reaction force on the terrain, recording shear force before failure occurred. Initial shear tests highlighted the importance of spine angle, with bioinspired anisotropic designs producing higher shear forces. Using this data, we placed the best (50○ angle) and worst (90○ angle) performing spines on the legs of our insect-scale ambulatory robot physical model. We then tested the robot on various surfaces at 0, 10 and 20○ inclines, seeing similar success with the more bioinspired spines.

Investigation of planar sliding deformation and analysis of the damage mechanism of a rocky landslide in Yaoping triggered by highway excavation in Hubei, China

During projects to build roads in China's mountainous areas, which are often characterized by the poor stability of rocky slopes, cases of deformation damage occur frequently. Because of the wide distribution of rocky landslides in the smooth layer, the unavoidable perturbation caused by engineering construction and the seriousness of landslide disasters, the destruction of this type of landslide and the research into prevention of the mechanism cannot be ignored. On 6 February 2023, a rock slide occurred in Yaoping village, Hubei Province, China. Using field investigations, Google satellite images, unmanned aerial vehicle photography, indoor testing and numerical simulations, we analysed the geological situation, deformation characteristics, damage process and triggering mechanism. The results show that the Yaoping landslide is a typical downward plane-sliding rock slide induced by the excavation of a highway. When strain softening occurs, the shear strength and friction coefficient of the slip zone soil are significantly reduced. Excavation caused the factor of safety of the slope to decrease substantially, with a maximum decrease rate of 60.7%. Excavation is considered to be the extrinsic factor that triggered the occurrence of the Yaoping landslide, while the reduction of landslide resistance caused by strain softening of the soil in the slip zone is the intrinsic direct factor that led to the occurrence of this type of landslide. The Yaoping landslide has obvious traction landslide characteristics. The landslide from deformation to destruction has four stages: creep at the leading edge of the landslide; traction deformation in the middle and back of the landslide; slip belt softening; and integral sliding. The prevention and control of this type of landslide requires a larger scope and depth of investigation, in order to identify in advance the possible soft surface in the rock layer, to speculate on the possible formation of landslide destruction mode, and to determine the support scheme and scope according to the geological conditions of the slopes on both sides of the highway. The slip zone soil of the Yaoping landslide was used to obtain the strength index of slip zone soil, which provides data support for the overall deformation characterization of the landslide. The results can provide a reference for the risk management and prevention of rock slides caused by human engineering activities during the excavation of roads.

Microstructural characteristics with process-microstructure-property relations during high-frequency ultrasonic vibration-assisted cutting of metallic material

Microstructural characteristics of chips and machined surfaces are influenced by the multiphysics fields distribution. This study investigates the multiphysics-induced microstructural deformation behaviors of CuZn37 metallic alloy during high-frequency ultrasonic vibration-assisted cutting (HFUVAC) and conventional cutting (CC). One the one hand, the multiphysics field distribution was established to clarify the chip formation of cutting characteristics and transient deformation process. The multiphysics field distribution of HFUVAC exhibited periodic changes due to tool intermittent movement, resulting in reduced cutting temperature and force. This intermittent movement also enhanced the sharpening shear effect due to instantaneous impact stress, transitioning from fragmented quasi-shear strain to continual multiple-shear strain during chip formation. One the other hand, the microstructural changes were examined to explain material removal mechanisms. The microstructure of CC demonstrated grain refinement and dislocation slip induced by friction and significant shear deformation. The microstructure of HFUVAC revealed the formations of dynamic recrystallization, twinning structures, and stacking faults, which were associated with enhanced plastic activity and limited slipping due to high-frequency impacts. The work reveals the response of the workpiece microstructure under the composite effects of high-frequency impacts and cutting process, which provides theoretical basis for the microstructure modification design through cutting technology.

Innovative design and construction of a closure joint for inland-river immersed tunnels via dry-land construction methods: A case study of the Yuliangzhou tunnel in China

Closure joints constructed to fill the spaces between immersed tunnel elements or between the tunnel elements and adjacent cut-and-cover tunnels are crucial for the longitudinal stability of immersed tunnels and affect the overall cost and duration of tunnel construction. To avoid the obstruction of navigation and reduce the difficulty of constructing closure joints, dry-land construction methods have been widely applied to construct closure joints for inland-river immersed tunnels, in particular using procedures involving axial dry docks. However, the traditional dry-land construction method has many inherent drawbacks. For example, the construction of underwater large-scale reinforced concrete antiretreat structures involves many underwater works, complicated construction processes, long operation time spans and high costs. Based on the Yuliangzhou immersed tunnel in China, a new dry-land construction method for closure joints of inland-river immersed tunnels based on tunnel–soil interface friction was developed to address the abovementioned problems. Considering the adverse influences of back-silting sediment on tunnel–soil interface friction, large-scale laboratory and onsite shear tests were carried out to derive the interface friction coefficients between the tunnel element base slabs and prelaid pebble foundation beds. A composite concrete steel sandwich (CCSS) water-retaining system was designed and assembled to separate the water in the dry dock from the river course. A simplified analysis method based on numerical simulations for the determination of the equivalent horizontal thrust P applied to element ES caused by the dewatering of the axial dry dock was proposed. Based on horizontal antisliding stability analyses of the tunnel elements during the axial dry dock dewatering stage, equations for the key design parameters of the new dry-land construction method were established. Through examination of the static equilibrium of the tunnel elements in the tunnel longitudinal direction, temporary longitudinal displacement constraint (LDC) structures at the immersion joints were designed. Furthermore, the following key construction techniques for the new dry-land construction method were systematically designed: installation of a CCSS water-retaining system at the entrance of the axial dry dock, water sealing at contact gaps, installation of finish-rolled screw-thread (FRST) steel bars as the LDC structures at the immersion joints, and construction of rigid connections between tunnel element ES and the cut-and-cover tunnel. Finally, onsite observation of the deformation states of Gina gaskets and monitoring of the tensile forces of FRST steel bars at the immersion joints verified the successful implementation of the new dry-land construction method, supporting the use of these techniques in closure joint design and construction for inland-river immersed tunnels.

Influence of confining pressure on rock fracture propagation under particle impact

Revealing the influence of confining pressure on the propagation and formation mechanism of rock cracks under particle impact is significant to deep rock excavation. In this study, the three-dimensional fracture reconstruction of the rock after particle impact was carried out by CT scanning, and the stress and crack field evolution of the rock under particle impact were analyzed by PFC2D discrete element numerical simulation. The results demonstrate that after particles impact, a fracture zone and intergranular main crack propagation zone are formed in the rock. The shear stress and tensile stress caused by compressive stress are the main reasons for the formation of the fracture zone, while the formation of the intergranular main crack propagation zone is mainly due to tangential derived tensile stress. The confining pressure induces prestress between rock particles such that the derived tensile stress needs to overcome the initial compressive stress between the particles to form tensile fractures. And the increase in the confining pressure leads to increases in the proportion of shear cracks and friction effects between rock particles, resulting in an increase in energy consumption for the same number of cracks. From a macroscopic perspective, the confining pressure can effectively inhibit the generation of cracks.