Subsurface Stress Research Articles

Influence of shot-peening on the self-heating behavior and fatigue properties of 300M steel

Shot peening is an established cold working process used to introduce residual compressive stresses on a surface and is extensively studied using conventional fatigue tests. However, it has not been widely studied using the self-heating method. Specifically, the heterogeneity of the dissipation field has not been estimated, with only an average approach being used. Previous investigations in the case of 300M steel demonstrated that the effect of shot peening on the high cycle fatigue properties can be either beneficial or detrimental. This study proposes to apply the self-heating method on polished 300M and to investigate the effect of mean stress and shot peening on the dissipation behavior. A modified self-heating model is proposed and calibrated for 300M steel. Combined with residual stress profiles, a method to compute and determine the shot peening effect on self-heating behavior through single point surface measurements is proposed. Application on 300M steel shows excellent results, the over-dissipation being mainly due to the sub-surface compressive residual stresses. The self-heating method has proven useful to quickly estimate fatigue properties of polished 300M steel. Based on the understanding of the self-heating curve of shot peened 300M steel, a quantification of shot-peening effect on fatigue limit is discussed.

Novel application of unsupervised machine learning for characterization of subsurface seismicity, tectonic dynamics and stress distribution

Our study pioneers an innovative use of unsupervised machine learning, a powerful tool for navigating unclassified data, to unravel the complexities of subsurface seismic activities and extract meaningful patterns. Our central objective is to comprehensively characterize seismicity within an active region by identifying distinct seismic clusters in spatial distribution, thereby gaining a deeper understanding of subsurface stress distribution and tectonic dynamics. Employing a diverse range of clustering algorithms, with particular emphasis on Fuzzy C-Means (FCM), our research meticulously dissects the intricate physical processes that govern a complex tectonic zone. This technique effectively delineates distinct tectonic zones, aligning seamlessly with established seismological knowledge and underscoring the transformative potential of Artificial Intelligence (AI) in analyzing regional subsurface phenomena, even under conditions of data scarcity. Moreover, associating earthquakes with specific seismogenic structures significantly enhances seismic hazard analyses, potentially paving the way for autonomous insights that inform engineering hazard assessments.

Nano-tribological behavior and structural evolution of 304 stainless-steel by molecular dynamics simulation and experiment

304 stainless-steel has excellent mechanical properties and is commonly used in ultra-precision instrumentation. Nevertheless, the research on the intricate nano tribological behavior of 304 stainless-steel during ultra-precision machining remains limited. In this work, the tribological behavior of 304 stainless-steel is investigated at different indentation depths and scratching velocities by molecular dynamics (MD) simulations and nano-scratch tests. The results show that higher indentation depths lead to more serious damage on the surface and subsurface of 304 stainless-steel. The friction force and friction coefficient also increase significantly with higher indentation depths. It is worth noting that the dislocation density is much smaller at the low-indentation depth, which is due to the large-scale dislocation annihilation at this depth. As the scratch velocity increases, the subsurface shear stress decreases, the dislocation length rises, and it is accompanied by the generation of V-shaped dislocations, which are caused by dislocation entanglement within the substrate. In addition, nano-scratch tests were performed and similar trends were obtained by comparing the results with simulations. This work provides theoretical guidance for a deeper understanding of the deformation behavior of 304 stainless-steel during nano-scratching and its engineering applications at the micron and nano-meter scales.

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

BackgroundA recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness.ObjectiveHerein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness.MethodsNear-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness.ResultsMeasured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter.ConclusionThe new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

Temporal Behavior of Glacially Induced Stresses and Strains at Potential Sites for Long‐Term Storage of Used Nuclear Fuel in Canada

AbstractContinental‐scale glaciations cause deformation, geopotential, rotation and stress changes of the Earth. Subsurface stress changes have implications to future activities such as carbon capture and storage, enhanced oil recovery and deep geological disposal of nuclear waste. We model glacially induced stresses, strain changes and deformation for North America, with emphasis on the two potential sites for long‐term storage of used nuclear fuel in Canada (Saugeen Ojibway Nation (SON)‐South Bruce area in southwestern Ontario and Wabigoon Lake Ojibway Nation (WLON)‐Ignace area in northwestern Ontario). We apply a revised, high‐resolution ice history of the past glacial cycle from the University of Toronto Glacial Systems Model, assumed to be representative for future glacial cycles, together with a set of seven different one‐ and three‐dimensional earth structures. We find that glacially induced stresses and strains can vary strongly throughout a glacial cycle, whereas especially the horizontal components can change from tensional to compressive in nature. Such changes can happen within a few 1,000 years, caused by drastic and rapid ice thickness increase or decrease above the potential site. Despite SON‐South Bruce being located further away from the ice sheet center than WLON‐Ignace and temporarily in the forebulge of the developing ice sheet during glaciation, stresses and strains are very similar in magnitude and range at both sites. We also see the potential that the glacially induced stresses can alter the direction of the pre‐existing maximum horizontal stress at SON‐South Bruce. These results will be incorporated in the site safety and site selection process.

A Systematic Review of Modeling and Simulation for Precision Diamond Wire Sawing of Monocrystalline Silicon.

Precision processing of monocrystalline silicon presents significant challenges due to its unique crystal structure and chemical properties. Effective modeling and simulation are essential for advancing the understanding of the manufacturing process, optimizing design, and refining production parameters to enhance product quality and performance. This review provides a comprehensive analysis of the modeling and simulation techniques applied in the precision machining of monocrystalline silicon using diamond wire sawing. Firstly, the principles of mathematical analytical model, molecular dynamics, and finite element methods as they relate to monocrystalline silicon processing are outlined. Subsequently, the review explores how mathematical analytical models address force-related issues in this context. Molecular dynamics simulations provide valuable insights into atomic-scale processes, including subsurface damage and stress distribution. The finite element method is utilized to investigate temperature variations and abrasive wear during wire cutting. Furthermore, similarities, differences, and complementarities among these three modeling approaches are examined. Finally, future directions for applying these models to precision machining of monocrystalline silicon are discussed.

Analysis investigation of the influence of sub-surface shear stress distribution of spur gear

Spur gears endure contact fatigue loads that can lead to surface damage on the gear teeth. Contact fatigue typically arises from dedendum during engineering and experiments, primarily caused by maximum sub-surface shear stress. This study presents a contact model incorporating profile-shift to examine sub-surface shear stress in relation to the occurrence of tooth root pits. Accurate calculations are performed to determine the distribution of sub-surface stress and meshing duration, considering various modification coefficients. The geometric cause affecting the shear stress near the tooth root is found. A deviation coefficient from base circle is proposed to analyze the influence of modification coefficient and pressure angle, which can be used in design reference. The investigation comprehensively explores the effects of profile-shift and pressure angle of spur gears on stress distribution.

Leveraging the ETAS model to forecast mining microseismicity

SUMMARY Mining operations result in changes of the subsurface stress field that can lead to the occurrence of microseismic events. The development of strategies for forecasting and avoidance of significant events is crucial for safe and efficient operations of mines. One such example, discussed here is the observed induced microseismicity in soft rock potash mines. It is primarily driven by the rock excavations but can also be triggered by preceding events or can result from the delayed effects of plastic creep of soft rocks. Therefore, it is important from seismic hazard assessment and risk mitigation points of view to understand the statistical aspects of microseismicity in potash or other types of mines. In this study, the temporal evolution of the induced microseismicity from a potash mine in Saskatchewan is analysed and modelled. Specifically, the epidemic type aftershock sequence model is used to approximate the occurrence rate of the induced mining microseismicity. The estimated parameters signify that the microseismicity displays swarm-type characteristics with limited inter-event triggering. Moreover, the Bayesian predictive framework is used to compute the probabilities of the occurrences of the largest expected events above a certain magnitude for prescribed forecasting time intervals during the evolution of the sequence. This approach for computing the probabilities allows one to incorporate fully the uncertainties of the model parameters. The Markov Chain Monte Carlo sampling of the posterior distribution are used to generate parameter chains to quantify their variability. Furthermore, several statistical tests are conducted to assess the credibility of the obtained retrospective forecasts compared to the observed microseismicity. The obtained results show that the developed approach can accurately forecast the number of events and intensity of the sequence. It also provides a framework for computing the probabilities for the largest expected events.

Progressive Induction Hardening: Measurement and Alteration of Residual Stresses

Progressive induction hardening is an in-line steel heat treatment method commonly used to surface harden powertrain components. It produces a martensitic case layer with a sharp transition zone to the base material. This rapid process will induce large residual stresses, where a compressive state in the case layer will shift to a tensile state in the transition zone. For fatigue performance, it is important to quantify the magnitude and distribution of these stresses, and moreover how they depend on material and processing parameters. In this work, x-ray diffraction in combination with a layer removal method is used for efficient and robust quantification of the subsurface stress state, which combines electropolishing with either turning or milling. Characterization is done on C45E steel samples that were progressively induction hardened using either a fast or slow (27.5 or 5 mm/s, respectively) scanning speed. The results show that although the hardening procedures will meet arbitrary requirements on surface hardness, case depth and microstructure, the subsurface tensile stress peak magnitude is doubled when using a fast scanning speed. However, the near-surface compressive residual stresses are comparable. In addition, the subsurface tensile residual stress peak is compared with the on-surface tensile stresses in the fade-out zone.

An efficient 3D finite element procedure for simulating wheel–rail cyclic contact and ratcheting

Various models for simulating rail ratcheting behaviour were developed to study rolling contact fatigue (RCF) damage in rails. However, limitations remain in terms of the accuracy of wheel–rail contact modelling and computational efficiency of the cyclic loading simulation. This study developed an efficient 3D finite element (FE) procedure to simulate ratcheting in rails subjected to numerous load cycles. The procedure simulates a wheel rolling repeatedly over a rail section with updated stress–strain states, enabling automatically executed cyclic loading simulation given a predefined number of cycles. To ensure the accuracy of the contact modelling, the effect of meshing schemes on subsurface stress distribution was examined. In addition, the FE contact model with the selected meshing scheme, which balances accuracy and computational efficiency, was verified against the widely accepted CONTACT program. Subsequently, a non-linear kinematic hardening (NLKH) steel material was used in the FE model for ratcheting simulations with up to 100 wheel-loading cycles. The rail surface and subsurface stress states were replicated under partial-slip wheel–rail rolling contact conditions with traction coefficients of 0.10, 0.20 and 0.35, respectively. The ratcheting behaviour was extensively analysed in terms of plastic deformation, contact patch evolution, and ratcheting rates. The simulated plastic deformation was found to alter the contact geometry and thus contact stresses, which in turn affect further accumulation of plastic deformation and subsequent ratcheting strains. These findings highlighted the importance of considering the interplay between the rail ratcheting behaviour of the rail and evolving contact conditions for predicting ratcheting and RCF damage in rails.

4D Electrical Resistivity Imaging of Stress Perturbations Induced During High‐Pressure Shear Stimulation Tests

AbstractFluid flow through fractured media is typically governed by the distribution of fracture apertures, which are in turn governed by stress. Consequently, understanding subsurface stress is critical for understanding and predicting subsurface fluid flow. Although laboratory‐scale studies have established a sensitive relationship between effective stress and bulk electrical conductivity in crystalline rock, that relationship has not been extensively leveraged to monitor stress evolution at the field scale using electrical or electromagnetic geophysical monitoring approaches. In this paper we demonstrate the use time‐lapse 3‐dimensional (4D) electrical resistivity tomography to image perturbations in the stress field generated by pressurized borehole packers deployed during shear‐stimulation attempts in a 1.25 km deep metamorphic crystalline rock formation.

Untangling the environmental and tectonic drivers of the Noto earthquake swarm in Japan.

The underlying mechanism of the ongoing seismic swarm in the Noto Peninsula, Japan, which generates earthquakes at 10 times the average regional rate, remains elusive. We capture the evolution of the subsurface stress state by monitoring changes in seismic wave velocities over an 11-year period. A sustained long-term increase in seismic velocity that is seasonally modulated drops before the earthquake swarm. We use a three-dimensional hydromechanical model to quantify environmentally driven variations in excess pore pressure, revealing its crucial role in governing the seasonal modulation with a stress sensitivity of 6 × 10-9 per pascal. The decrease in seismic velocity aligns with vertical surface uplift, suggesting potential fluid migration from a high-pore pressure zone at depth. Stress changes induced by abnormally intense snow falls contribute to initiating the swarm through subsequent perturbations to crustal pore pressure.

Effect of surface rolling process on rolling contact fatigue behavior and failure mechanism of powder metallurgy steel

The effect of surface rolling process on the surface microstructure and rolling contact fatigue of the Fe-2Cu-0.6 C powder metallurgy steel was investigated in the present investigation. Results indicated that a densified and hardened layer with a densification depth of 330 μm and a surface hardness of 330 HV0.1 was generated in the surface layer after rolling process. Ferrite grain and pearlite lamellae became typical fibrous structures on the top surface. The microstructure of pearlite was presented by two typical features. One was that the discrete cementite plates were severely curled and wavy. The other one was that the cementite plates remained parallel to each other, but were a reticular structure at a macroscopic level. The rolling contact fatigue (RCF) test showed that the RCF life of the rolled sample was superior. The L10, L50, L63.2 life increased by 182%, 105%, 92%, respectively. Surface initiated spalling was the main fatigue failure mode. Subsurface equivalent contact stress and local equivalent stress were calculated. The results showed that surface cracks were due to the repetitive tensile stress, which caused pits. Subsurface cracks nucleated and propagated in the region where the local equivalent stress was higher than the matrix yield strength, which caused spalling as connecting with surface cracks. The surface densified layer plays an important role in improving the rolling fatigue resistance of the material.

The effect of highly elongated micro-contacts on rolling contact stress field

This study presents a boundary element model to analyze contact pressure distribution and the subsurface stress field in rough rolling elements. The methodology is demonstrated by the stress field of the backup roll and work roll in the cold/temper rolling process and characterized by a parallel orientation of roughness lay with rolling direction, resulting in a cluster of highly elongated elliptical micro-contacts. The numerical outcomes revealed that the amplitude of in-plane and out-of-plane shear stress components are strongly dependent on the ellipticity of the micro-contacts. Comparison with experimental results shows that the crack plane is oriented transversal to the rolling direction and the crack initiation location corresponds to the location where the shear stress components are maximum.

Elastic and Elastoplastic Contact Mechanics of Concentrated Coated Contacts

Machines operate under increasingly harsher contact conditions, causing significant wear and contact fatigue. Sub-surface stresses are responsible for the premature contact fatigue of rolling element bearings, meshing gears, and cam–follower pairs. Surface protection measures include hard, wear-resistant coatings. Traditionally, contact integrity has been predicted using classical Hertzian contact mechanics. However, the theory is only applicable when the contact between a pair of ellipsoidal solids of revolution may be considered as a rigid indenter penetrating a semi-infinite elastic half-space. Many coatings act as thin bonded elastic layers that undergo considerably higher pressures than those predicted by the classical theory. Furthermore, inelastic deformation of bonded solids can cause plastic flow, work-hardening, and elastoplastic behaviour. This paper presents a comprehensive, integrated contact mechanics analysis that includes induced sub-surface stresses in concentrated counterformal finite line contacts for all the aforementioned cases. Generated pressures and deformation are predicted for hard coated surfaces, for which there is a dearth of relevant analysis. The contact characteristics, which are of particular practical significance, of many hard, wear-resistant advanced coatings are also studied. The paper clearly demonstrates the importance of using efficient semi-analytical, detailed holistic contact mechanics rather than the classical idealised methods or empirical numerical ones such as FEA. The novel approach presented for the finite line contact of thin-layered bonded solids has not hitherto been reported in the open literature.

Post-mining related reactivation potential of faults hosted in tight reservoir rocks around flooded coal mines, eastern Ruhr Basin, Germany

The cessation of hard coal mining in the Ruhr Basin in 2018 marked the region's transition to the post-mining phase. Controlled mine water rebound induces changes in the subsurface stress conditions, as pore pressure increases locally. Presently, mine water rebound is observed in the eastern Ruhr Basin (water province “Haus Aden”) along with associated microseismicity. Furthermore, post-mining challenges might comprise the potential risk of fault reactivation, which is addressed in this study by conducting a fault slip assessment. Based on subsurface coal seam mapping data, a 3D structural model for the NE part of the “Haus Aden” water province has been constructed to serve as the basis for identifying the most vulnerable fault trends and types of the structural inventory. Slip tendency analysis, considering normal faulting conditions, revealed NW-SE to NNW-SSE trending normal faults to be most susceptible to reactivation. Probabilistic fault slip assessment, focused on NW-SE to NNW-SSE trending normal faults mapped within the “Heinrich-Robert” colliery, show no fault reactivation potential for a mine water rebound up to a level of 640 m below ground. Assuming hydrostatic conditions in the vicinity of the faults, friction coefficients are only partially exceeded for high differential stresses. In addition, a novel workflow is used to model the spatial variability of the frictional fault strength as input for a fault stability analysis, exemplified for a selected NNW-SSE trending normal fault. For considering hydrostatic pore pressure, results show that the fault consists mainly of stable, but also unstable, horizontally elongated patches. These findings question the conventional simplified approach of using a single constant friction coefficient for fault stability analysis.

High-efficiency green machining of single crystal 4H–SiC based on tribo-oxidation

High efficiency, high quality and green machining of single crystal silicon carbide (SiC) is an important issue in the third-generation semiconductor industry. In this paper, a novel machining method for single crystal SiC based on tribo-oxidation is proposed. The formula and preparation process of polysaccharide bonded soft abrasive tool were designed. Dry machining of C-face of 4H–SiC substrate was carried out with the prepared environmentally friendly abrasive tool sample. The material removal mechanism of the proposed machining method was preliminarily analyzed, and the material removal rate, surface roughness and subsurface residual stress were studied. The experimental results show that the maximum material removal rate of 4H–SiC can reach 1.03 μm/min with a corresponding average surface roughness of Sa 0.816 nm. The machined surface has no brittle flaw, and subsurface residual compressive stress exists with a maximum value of 58.9 MPa. The material removal mainly attributed to the active oxidation of SiC surface induced by the friction between alumina abrasives and SiC substrate. The proposed machining method has potential application value in thinning of SiC wafers.

A simplified spherical roller bearing model and its application in the wind turbine main bearing system finite element modeling

Different from most bearing design guidelines, deformation of bearing rings and supporting structures usually influences the bearing performance significantly. Finite element analysis (FEA) can be used in bearing system design considering the structure deformation, but the contact region between rolling elements and raceways modeling is very complex and usually causes non-convergent problems. As to a spherical roller bearing (SRB), the model must also consider both its misalignment ability and roller contact stiffness. This paper presents a simplified SRB model considering the angular misalignment ability. In order to define the SRB roller raceway load deformation relationship, a lamina model is developed. And this simplified model is validated by solid roller model of a bearing sector. A wind turbine main bearing system is analyzed using the developed SRB model. Load distribution considering the system deformation and angular misalignment are discussed. With the help of fine meshed solid elements roller raceway contact model, the raceway contact pressure and subsurface stress distribution can also be obtained.

Two-phase flow thermo-hydro-mechanical modeling for a water flooding field case

Simulation of subsurface energy system involves multi-physical processes such as thermal, hydraulical, and mechanical (THM) processes, and requires a so-called THM coupled modeling approach. THM coupled modeling is commonly performed in geothermal energy production. However, for hydrocarbon extraction, we need to consider multiphase flow additionally. In this paper, we describe a three-dimensional numerical model of non-isothermal two-phase flow in the deformable porous medium by integrating governing equations of two-phase mixture in the porous media flow in the reservoir. To account for inter-woven impacts in subsurface conditions, we introduced a temperature-dependent fluid viscosity and a fluid density along with a strain-dependent reservoir permeability. Subsequently, we performed numerical experiments of a ten-year water flooding process employing the open-source parallelized code, OpenGeoSys. We considered different well patterns with colder water injection in realistic scenarios. Our results demonstrate that our model can simulate complex interactions of temperature, pore pressure, subsurface stress and water saturation simultaneously to evaluate the recovery performance. High temperature can promote fluid flow while cold water injection under non-isothermal conditions causes the normal stress reduction by significant thermal stress. Under different well patterns the displacement efficiency will be changed by the relative location between injection and production wells. This finding has provided the important reference for fluid flow and induced stress evolution during hydrocarbon exploitation under the environment of large reservoir depth and high temperature.

Effect of grain boundary on scratch behavior of polycrystalline copper

The anisotropy in the elastoplastic response of crystalline solids influences substantially their scratch resistance at the microscale. While grain boundaries typically act as obstacles to the motion of dislocations at the grain level, the scratch behavior in the vicinity of the grain boundary is influenced by other factors such as crystallographic orientation and pile-up topography. We performed a systematic set of nano-scratch simulations using the mechanism-based strain gradient crystal plasticity to study the evolution of scratch force and depth near grain boundaries. To validate our model, we conducted a nano-scratch test on a polycrystalline copper sample and compared the scratch depth profile for a specific grain boundary with the simulated result, where a good qualitative agreement was achieved. Our simulations showed that the scratch depth, force, and hardness vary between the corresponding values for the individual constitutive grains, and the variation decreases by reducing the grain size. Additionally, we analyzed the scratch response in terms of the pile-up topography and subsurface stresses and distinguished different regimes when the indenter approaches and scratches across the boundary. Our findings offer a new direction to optimize the scratch resistance of polycrystalline metals by tailoring the size and orientation of grains near the surface. Additionally, it introduces scratching as a robust material characterization method.