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Behavior of mode I crack tip in fiber metal laminate (FML) differs from that in homogeneous or plain specimen made of metal used in the laminate due to the load transfer effect in the laminate caused by property mismatch between dissimilar material layers. The purpose of this paper is to present a finite element investigation on the characteristics of crack tip in monotonically loaded and residually stressed FML.

Crack tip characteristics are assessed by: the sizes of various zones that form at the tip; and crack tip energy release rates. The same are found by modeling two types of Glare laminates under monotonic tension with different crack orientations in SSY regime – Type I and Type II. Residual stresses are externally introduced in the models. Delaminations are modeled by cohesive elements. Crack tip zone sizes are measured from finite element solutions. Values of J integrals are computed over cyclic paths near the crack tips. Identically cracked and loaded plain aluminum alloy specimens are also modeled for comparison.

The sizes of crack tip zones in Glare laminates are found to be different than those in plain specimens. Process zone is observed to form at crack tip in Type I laminate whereas it does not develop in Type II laminate, the reverse being true in plain specimens. Values of J integrals near crack tips are also found to deviate from those in plain specimens, higher in Type I laminate due to crack tip stress amplification and lower in Type II laminate due to stress reduction. Crack orientation decides the amplification or shielding effect in the laminate.

There is scope for validating the numerical results reported in the paper by theoretical models.

The method to quantify crack tip shielding and amplification is presented that shall be useful in checking the structural integrity/safety of the laminate during actual service conditions.

Shielding and amplification effects are explicitly described and illustrated in the paper. Suitability of using J integrals over paths crossing non-homogeneous and property mismatched material layers is tested. Use of cohesive zone method that is readily applicable in finite element procedures and is relatively simple, fast and reasonably accurate is also demonstrated.

The induction of geological disasters is predominantly influenced by the dynamic evolution of the stress and plastic zones of the multilayer rock formations surrounding deep-rock roadways, and the behaviours and mechanisms of high in situ stress are key scientific issues related to deep-resource exploitation. The stress environment of deep resources is more complex owing to the influence of several geological factors, such as tectonic movements and landforms. Therefore, in practical engineering, the in situ stress field is in a complex anisotropic three-dimensional state, which may change the deformation and failure law of the surrounding rock. The purpose of this study is to investigate the tunnelling-induced stress and plastic evolution causing instability of multilayered surrounding rock by varying three-dimensional in situ stresses.

Based on data from the Yangquan Coal Mine, China, a finite difference model was established, and the elastic-plastic constitutive model and element deletion technology designed in the study were analysed. Gradual tunnelling along the roof and floor of the coal seam was used in the model, which predicted the impact tendency, and compared the results with the impact tendency report to verify the validity of the model. The evolutions of the stress field and plastic zone of the coal roadway in different stress fields were studied by modifying the maximum horizontal in situ stress, minimum horizontal in situ stress and lateral pressure coefficient.

The results shown that the in situ stress influenced the stress distribution and plastic zone of the surrounding rock. With an increase in the minimum horizontal in situ stress, the vertical in situ stress release area of the roof surrounding rock slowly decreased; the area of vertical in situ stress concentration area of the deep surrounding rock on roadway sides decreased, increased and decreased by turn; the area of roof now-shear failure area first increased and then decreased. With an increase in the lateral pressure coefficient, the area of the horizontal in situ stress release area of the surrounding rock increased; the area of vertical in situ stress release area of the roof and floor surrounding rock first decreased and then increased; the area of deep stress concentration area of roadway sides decreased; and the plastic area of the surrounding rock and the area of now-shear failure first decreased and then increased.

The results obtained in this study are based on actual cases and reveal the evolution law of the disturbing stress and plastic zone of multilayer surrounding rock caused by three-dimensional in situ stress during the excavation of deep rock roadways, which can provide a practical reference for the extraction of deep resources.

This study aims to analyse the deep resource mining that causes high in situ stress, and the disturbance of tunnelling and mining which may induce large stress concentration, plastic deformation and rock strata compression deformation. The depth of deep resources, excavation rate and multilayered heterogeneity are critical factors of excavation disturbance in deep rock. However, at present, there are few engineering practices used in deep resource mining, and it is difficult to analyse the high in situ stress and dynamic three-dimensional (3D) excavation process in laboratory experiments. As a result, an understanding of the behaviours and mechanisms of the dynamic evolution of the stress field and plastic zone in deep tunnelling and mining surrounding rock is still lacking.

This study introduced a 3D engineering-scale finite element model and analysed the scheme involved the elastoplastic constitutive and element deletion techniques, while considering the influence of the deep rock mass of the roadway excavation, coal seam mining-induced stress, plastic zone in the process of mining disturbance of the in situ stress state, excavation rate and layered rock mass properties at the depths of 500 m, 1,500 m and 2,500 m of several typical coal seams, and the tunnelling and excavation rates of 0.5 m/step, 1 m/step and 2 m/step. An engineering-scale numerical model of the layered rock and soil body in an actual mining area were also established.

The simulation results of the surrounding rock stress field, dynamic evolution and maximum value change of the plastic zone, large deformation and settlement of the layered rock mass are obtained. The numerical results indicate that the process of mining can be accelerated with the increase in the tunnelling and excavation rate, but the vertical concentrated stress induced by the surrounding rock intensifies with the increase in the excavation rate, which becomes a crucial factor affecting the instability of the surrounding rock. The deep rock mass is in the high in situ stress state, and the stress and plastic strain maxima of the surrounding rock induced by the tunnelling and mining processes increase sharply with the excavation depth. In ultra-deep conditions (depth of 2,500 m), the maximum vertical stress is quickly reached by the conventional tunnelling and mining process. Compared with the deep homogeneous rock mass model, the multilayered heterogeneous rock mass produces higher mining-induced stress and plastic strain in each layer during the entire process of tunnelling and mining, and each layer presents a squeeze and dislocation deformation.

The results of this study can provide a valuable reference for the dynamic evolution of stress and plastic deformation in roadway tunnelling and coal seam mining to investigate the mechanisms of in situ stress at typical depths, excavation rates, stress concentrations, plastic deformations and compression behaviours of multilayered heterogeneity.

This study aims to clarify the evolution law of stress field and fracture field during the mining process of inclined coal seam, to prevent the occurrence of roof burst water and impact ground pressure accident during the advancing process of working face.

The evolution law of stress-fracture field under different mining conditions of inclined coal seam was studied by using discrete element method and similar material simulation method.

The overburden stress at the lower end of the coal seam was mainly transmitted to the deep rock mass on the left side, and the overburden stress at the upper end was mainly transmitted to the floor direction. With the increase of the inclined length of the mining coal seam, the development of the fracture zone gradually evolves from the “irregular arch” form to the “transversely developed trapezoid” form. The development range of the fracture zone was always in the internal area of the stress concentration shell.

An original element of this paper is based on the condition that the dip angle of coal seam is 35°, and the evolution law of overburden stress-fracture field during the excavation of coal seam with different lengths was analyzed by UDEC numerical simulation software. The coupling relationship between stress shell and fracture field was proposed, and the development range of fracture zone was determined by stress. The value of this paper is to provide technical support and practical basis for the safety production of a mine working face.

This paper aims to propose a deployment optimization and efficient synchronous acquisition method for compressive stress sensors used by stress distribution law research based on the genetic algorithm and numerical simulations. The authors established a new method of collecting the mining compressive stress-strain distribution data to address the problem of the number of sensors and to optimize the sensor locations in physical similarity simulations to improve the efficiency and accuracy of data collection.

First, numerical simulations were used to obtain the compressive stress distribution curve under specific mining conditions. Second, by comparing the mean square error between a fitted curve and simulation data for different numbers of sensors, a genetic algorithm was used to optimize the three-dimensional (3D) spatial deployment of sensors. Third, the authors designed an efficient synchronous acquisition module to allow distributed sensors to achieve synchronous and efficient acquisition of hundreds of data points through a built-in on-board database and a synchronous sampling communication structure.

The sensor deployment scheme was established through the genetic algorithm, A synchronous and selective data acquisition method was established for reduced the amount of sensor data required under synchronous acquisition and improved the system acquisition efficiency. The authors obtained a 3D compressive stress distribution when the advancement was 200 m on a large-scale 3D physical similarity simulation platform.

The proposed method provides a new optimization method for sensor deployment in physical similarity simulations, which improves the efficiency and accuracy of system data acquisition, providing accurate acquisition data for experimental data analysis.

Sufficient sample data are the necessary condition to ensure high reliability; however, there are relatively poor fatigue test data in the engineering, which affects fatigue life's prediction accuracy. Based on this, this research intends to analyze the fatigue data with small sample characteristics, and then realize the life assessment under different stress levels.

Firstly, the Bootstrap method and the principle of fatigue life percentile consistency are used to realize sample aggregation and information fusion. Secondly, the classical outlier detection algorithm (DBSCAN) is used to check the sample data. Then, based on the stress field intensity method, the influence of the non-uniform stress field near the notch root on the fatigue life is analyzed, and the calculation methods of the fatigue damage zone radius and the weighting function are revised. Finally, combined with Weibull distribution, a framework for assessing multiaxial low-cycle fatigue life has been developed.

The experimental data of Q355(D) material verified the model and compared it with the Yao’s stress field intensity method. The results show that the predictions of the model put forward in this research are all located within the double dispersion zone, with better prediction accuracies than the Yao’s stress field intensity method.

Aiming at the fatigue test data with small sample characteristics, this research has presented a new method of notch fatigue analysis based on the stress field intensity method, which is combined with the Weibull distribution to construct a low-cycle fatigue life analysis framework, to promote the development of multiaxial fatigue from experimental studies to practical engineering applications.

This study aims to investigate the effect of microtextured tools on the geometric morphology of serrated chips, and further improve the cutting performance of polycrystalline cubic boron nitride (PCBN) tool and extend the tool life and the surface quality of the machined surface.

A three-dimensional finite element cutting model of hardened steel AISI D2 with microtextured PCBN tools were established using the finite element software Abaqus, and cutting tests were carried out. Furthermore, the stress distribution in the primary deformation zone was investigated based on the triaxiality of stress, and the influence of microtexture on the geometric morphology of serrated chips and crack development was researched.

The results show that compared with nontexture tools, elliptical pits and wavy grooves microtexture tools have lower serrated degree Gs, higher serrated frequency f per unit length and more miniature serrated step Pc. The serrated phenomenon is intensified because the tensile stress zone of chips generated by nontextured tools is longer than that of elliptic pits and wavy grooves microtexture tools. Simultaneously, the maximum value of triaxiality in the tensile stress zone achieved by nontexture tools is larger than that of the two microtexture tools, and chips obtained by nontextured tools are more susceptible to propagation fractures.

This paper mainly studies the effect of microtexture on chip microgeometry, which is relatively little studied at present. At the same time, this paper has a certain engineering significance for PCBN tool turning hardening steel.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0149/

This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon.

First, the origin of residual stresses is explored and a simple theoretical model is developed to predict residual stress distributions. Next, experimental methods are used to measure the residual stress profiles in a set of test samples produced with different process parameters.

Residual stresses are found to be very large in SLM parts. In general, the residual stress profile consists of two zones of large tensile stresses at the top and bottom of the part, and a large zone of intermediate compressive stress in between. The most important parameters determining the magnitude and shape of the residual stress profiles are the material properties, the sample and substrate height, the laser scanning strategy and the heating conditions.

All experiments were conducted on parts produced from stainless steel powder (316L) and quantitative results cannot be simply extrapolated to other materials. However, most qualitative results can still be generalized.

This paper can serve as an aid in understanding the importance of residual stresses in SLS/SLM and other additive manufacturing processes involving a localized heat input. Some of the conclusions can be used to avoid problems associated with residual stresses.

This paper aims to present an approach for the numerical simulation of concrete shrinkage. First, some physical mechanisms of shrinkage are described and then the developed numerical model for the analysis of shrinkage of spatial three-dimensional structures using thermal analogy is presented. Results of the real behavior of structures because of concrete shrinkage using the developed numerical model are compared with the experimental and it is clearly shown that the developed numerical model is an efficient tool in predicting the time-dependent behavior of all concrete structures.

In this paper, Fib Model Code 2010 to predict shrinkage deformation of concrete is used, and it was incorporated in the three-dimensional numerical model using the thermal analogy. Mentioned three-dimensional numerical model uses the modified Rankine material law to describe concrete behavior in tension and modified Mohr-Coulomb material law to describe concrete behavior in compression. The developed three-dimensional numerical model successfully analyzes the behavior of reinforced and/or prestressed concrete structures including time-dependent deformations of concrete as well.

Results are shown in this paper clearly demonstrate the reliability of the developed numerical model in predicting the shrinkage strain, as well as its impact on concrete and reinforced concrete structures. The results obtained using the developed numerical model are in better agreement with the experimental results, than the results obtained using the numerical models from literature that also use the Fib Model Code 2010 to predict the shrinkage strain. So, it can be concluded that for a real simulation of concrete structures, alongside the model for predicting the shrinkage strain, the models for concrete behavior in tension and compression have a very important role.

Results of the developed three-dimensional numerical model were compared with experimental results from literature and with theoretical foundations, and it can be talked that this numerical model presents a good tool for analysis of reinforced and prestressed concrete structures including shrinkage deformation of concrete. Results obtained using the developed three-dimensional numerical model are better agreed with experimental than results of other numerical model from literature.

The purpose objective of this study is to identify the friction coefficient and friction effect in electromagnetic upsetting (EMU) high-speed forming process.

Based on numerical simulation and upsetting experiment of 2A10 aluminum alloy bar, the friction coefficient between contact surfaces is obtained by combining the fitting displacement distribution function and the electromagnetic-mechanical coupling numerical model, and the influence of friction effect is analyzed.

The maximum impact velocity and acceleration during EMU are 13.9 m/s and −3.3 × 106 m/s², respectively, and the maximum strain rate is 7700 s⁻¹. The functional distribution relationship between friction coefficient combination (FS, FD) and characteristic parameters [upper diameter (D1) and middle diameter (D2)] is established. The values of FS and FD are 0.1402 and 0.0931, respectively, and the maximum relative error is 2.39%. By analyzing the distribution of equivalent stress and strain, it is found that plastic deformation has obvious zoning characteristics and there is serious failure concentration in the strong shear zone.

Friction coefficient significantly affects stress or strain distributions in material forming process, but it is difficult to obtain friction coefficients through experimental tests in the high-speed forming process. In this paper, a multi-field coupling numerical model is proposed to determine friction coefficients and applied to the electromagnetic impact loading process (a high-speed forming process).

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0154/