A comprehensive experiment-based approach to generate stress field and slip lines in cutting process

This study proposes a comprehensive experiment-based method to determine stress field and slip lines in metal cutting process. The chip geometry and workpiece's strain and strain rate fields are determined using an in-situ imaging technique. The two-dimensional (2D) heat transfer problem for the steady-state cutting process is solved to derive the cutting temperature, and the flow stresses of work material in the main deformation zone are calculated based on the plasticity theory. Furthermore, the stress field is comprehensively determined to satisfy the stress equilibrium, friction law along the tool-chip interface, and traction-free boundary condition along the uncut chip surface. In addition, slip lines in the main deformation zone are derived according to the direction of maximum shear stress without the assumption of perfect rigid-plastic material. The proposed method is validated by comparing the cutting forces calculated based on the obtained stress field with the experimentally measurements.

Study on Failure Mechanism and Phase Transformation of 304 Stainless Steel during Erosion Wear

In this paper, the failure mechanism and phase transformation process of 304 stainless steel during the erosion wear process were studied with a rotary erosion wear test device. The surface morphologies of the worn 304 stainless steel were investigated by scanning electron microscopy (SEM). The metallographic structures of the nonworn and worn 304 stainless steel were analyzed by optical microscope (OM) and transmission electron microscopy (TEM). In addition, the surface hardness on different areas of the sample was also measured. The results demonstrated that the failure mechanism of 304 stainless steel during the process of erosion wear was cutting and spalling caused by plastic deformation. The high-density dislocations move along the slip planes between slip lines, which resulted in the formation of martensite phase between the slip lines. Meanwhile, the martensitic transformation on the worn surface caused by severe plastic deformation was the coordination of dislocation martensite and twin martensite.

Ductile Tearing and Plastic Collapse Competition

Structures containing large cracks and made in ductile materials may experience two types of failure mechanisms: ductile tearing or plastic collapse. Under displacement controlled loading ductile tearing is a stable crack growth mechanism. Plastic collapse leads to a much faster damage evolution. Ductile tearing is the result of void growth and coalescence ahead of the crack front under the high strain concentration. This mechanism is slowed down by a high material hardening and under a high constraint. The global deformation of the structure is limited. Plastic collapse is induced by plastic strain accumulation along slip lines. Slip lines depend on the geometry of the cracked structures and of the type of loading. Therefore plastic collapse produces large deformations of the structure. Several studies (Nicak, 2009; Gilles, 2010; Le Delliou, 2017) on large ductile crack growth have been performed by Framatome, and EDF on deeply surface cracked plates made in Nickel base alloy 600. The tests were performed on Centre Cracked Tension specimens with a semi-elliptical surface crack. In this very tough material, the crack grew in its plane, but for large load levels, the plate was extremely deformed and a collapse mechanism appeared. More recently, Tests on Fixed Grip SE(T) specimens in Nickel base alloy 600 were performed by CEA showing a different type of transition between ductile tearing to collapse in function of the crack length. The paper analyzes these experiments and simulates the ductile tearing using node release methodology. The prediction of the apparition of the collapse is obtained by determining collapse load with large displacement modeling. From these results, a reconciliation of curves J-R of the CCT et SE(T) specimen will be done.

Upper-Bound Finite Element Adaptive Analysis of Plane Strain Heading in Soil with a Soft Upper Layer and Hard Lower Layer

This paper investigates the stability of a rectangular tunnel face affected by surcharge loading in soil with a soft upper layer and hard lower layer using upper-bound finite element methods with a plastic-dissipation-based mesh adaptive strategy (UBFEM-PDMA). Seven different positions for the soil interface are selected to study this problem. The upper bounds on the ultimate surcharge loads σs are presented in terms of dimensionless stability charts. The σs increases with tunnel depth, and it increases when the position of the soil interface moves up along the tunnel face. The failure mechanism primarily involves a wedge-shaped zone around the tunnel face and two slip lines originating from the top and bottom of the tunnel face, and it is mainly influenced by three factors, i.e., the position of the soil interface, the soil properties, and the tunnel depth. In contrast to the failure mechanism for uniform soil, multiple slip lines exist in the tunnel face in soil with a soft upper layer and hard lower layer. The results compare reasonably well with those in the literature and those from the numerical method.

Experimental and numerical analysis of deformation patterns in notched heterogeneous welds

Standardized weld flaw assessment techniques assume the weld region to be homogeneous which is a strong idealisation of reality. Characterising the effects of heterogeneous properties of welds through the analysis of deformation patterns and slip lines is the major concern of this research. It is the goal to investigate which effects these variations in properties within the weld material have on the propagation of cracks within the weld material. Performed experiments are SENT tests on strongly heterogeneous welded connections. The same material is also simulated with a weld heterogenisation model in ABAQUS®. Results from both experiments and simulations are discussed and compared. It is shown that slip lines tend to avoid zones of high hardness in a way that a path of least resistance is found. Related to this, it is seen that the slip line angles deviate from the theoretical 45° for homogeneous material. Obtained results validate the numerical model used.