Engineering Failure Analysis最新文献

{"title":"Investigating the effects of the moisture content of filling and shear rate on the shear characteristics of rock-like materials with joint","authors":"Yunjin Hu,&nbsp;Chenxing Tian,&nbsp;Caijun Shao,&nbsp;Yong Niu","doi":"10.1016/j.engfailanal.2025.109411","DOIUrl":"10.1016/j.engfailanal.2025.109411","url":null,"abstract":"<div><div>Rock joints in fault zones are commonly filled with fault gouge, where clay fillings are common. Until now, the shear characteristics of filled rock joints under different moisture contents and shear rates have not been well understood. This work investigates the mechanical behaviour of rock-like materials with clay-filled joints under compression-shear loading. A self-developed rock shear test system was used to conduct direct shear tests on rock-like materials under three normal stresses and five shear rates. Six types of natural red clay with different moisture contents were selected for filling. The coupling effects of the moisture content and shear rate on the mechanical properties of rock-like samples with clay-filled joints were investigated. Furthermore, the failure characteristics of the failure surfaces of rock-like materials after shearing were scanned via 3D scanning. The test results show that the moisture content of fillings and shear rate significantly affect the shear characteristics of rock-like materials with filled joints. The plastic limit moisture content is a critical point where the shear rate has the least effect on the shear strength. Under dry soil filling conditions, the degree of shear damage on the shear plane is the smallest. The present results can provide guidance for slope protection projects.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109411"},"PeriodicalIF":4.4,"publicationDate":"2025-02-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402885","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Moderate temperature wear behaviour of Magnesium-Dicalcium silicate composite","authors":"P. Kumaravelu,&nbsp;S. Arulvel,&nbsp;Jayakrishna Kandasamy,&nbsp;P. Jeyapandirajan","doi":"10.1016/j.engfailanal.2025.109413","DOIUrl":"10.1016/j.engfailanal.2025.109413","url":null,"abstract":"<div><div>This study investigates the effect of dicalcium silicate content on the moderate-temperature wear behaviour of magnesium-dicalcium silicate (AZ91D-Ca₂SiO₄) composites over a temperature range of 100 °C,150 °C, 200 °C and 250 °C. Various wear mechanisms were investigated in AZ91D-Ca₂SiO₄ composites under specific temperature conditions. AZ91D-Ca₂SiO₄ composites were fabricated with different weight percentages (2.5 %, 5 %, and 10 %) of Ca₂SiO₄ reinforcement using the stir casting process. Hardness, phase composition, wear depth, and morphological changes were observed in the composites after wear testing. The metal-oxide interaction regimes were precisely detailed through the tribology characterization. The results demonstrate a significant increase in wear rate as temperatures rise from 100 °C to 250 °C. Specifically, at temperatures around 100 °C and 150 °C, abrasive wear and oxidation were identified as the primary wear mechanisms. At moderate temperatures, around 250 °C, abrasive wear, plastic deformation, and delamination were the dominant wear mechanisms. The higher presence of Mg-Si and Mg-Ca phases, along with Ca₂SiO₄ particles, on the worn surfaces of the composites has reduced the oxidation of the AZ91D matrix at moderate temperatures. Furthermore, this study reports a detailed investigation into the influence of different weight percentages (2.5 %, 5 %, and 10 %) of Ca₂SiO₄ on the moderate-temperature wear behaviour of AZ91D and AZ91D-Ca₂SiO₄ composites.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109413"},"PeriodicalIF":4.4,"publicationDate":"2025-02-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Establishment of theoretical model and dynamic analysis of gear meshing force for the multi-gear driving system considering the effect of friction","authors":"He Bu,&nbsp;Jie Li,&nbsp;Jingbo Guo,&nbsp;Zhuyu Gao,&nbsp;Yuhang Zhao","doi":"10.1016/j.engfailanal.2025.109382","DOIUrl":"10.1016/j.engfailanal.2025.109382","url":null,"abstract":"<div><div>The coupling effect occurs in the force transmission between the pinions and the large gear ring in the multi-gear driving system. This interaction can easily lead to impacts and vibrations, resulting in wear and failure of the gear teeth, thereby threatening the operational safety of the entire gear system. In this paper, a theoretical model of meshing force of a multi-gear driving system considering friction is established based on the centralized parameter method, and a method to analyze the wear failure of gear teeth is proposed. Taking the shield machine main bearing multi-gear driving system as an example, the theoretical calculation of the time-varying meshing stiffness of the internal gears is carried out first. The theoretical value of the meshing force is calculated, and the relative error between it and the simulation value is calculated to be 2.95% by combining with the transient dynamics analysis. While the comparison verifies the correctness of the theoretical model of the proposed meshing force, the control threshold of the dynamic meshing force of the large gear ring is finally obtained as <span><math><mrow><mn>2</mn><mo>.</mo><mn>39</mn><mo>×</mo><mn>1</mn><msup><mrow><mn>0</mn></mrow><mrow><mn>5</mn></mrow></msup></mrow></math></span> N. The study shows that multiple drive units can lead to the coupling effect of the force on the large gear ring, and its service time is the key to determining the span of the system. An increase in the friction factor of the tooth surface will lead to shock and vibration in gear meshing, which will increase the wear of the gear teeth. Ensuring that the value of the meshing force is within the control threshold can make the drive system more stable. The method proposed in this study will guide the design, manufacture, and installation of multi-gear driving systems. It provides novel research insights and theoretical support for effectively preventing gear wear failure and has important engineering significance.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109382"},"PeriodicalIF":4.4,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387939","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Failure analysis and numerical modeling of a fractured chain element from a drawing machine in a metallurgical production plant","authors":"Ioannis Pressas,&nbsp;George Pantazopoulos","doi":"10.1016/j.engfailanal.2025.109406","DOIUrl":"10.1016/j.engfailanal.2025.109406","url":null,"abstract":"<div><div>Track-type chains are some of the most important production and transportation systems, commonly used in the industry. In the current research, the failure of a fractured chain element was investigated. The fractured material was evaluated via chemical analysis, optical metallography and hardness testing. In order to determine the failure mechanism, the fracture surface was evaluated using macro- and microfractography. The failure mode exhibited typical characteristics, of a microscopically brittle fracture, principally consistent to the occurrence of fatigue cracking followed by overload fracture. Fracture initiated from stress concentration areas and propagated all over the adjacent areas. Moreover, the microscopic fracture morphologies signify an almost uniform microcracking progressed under low-cycle fatigue conditions. The coarse carbide microstructure is suggestive for low fracture resistance, while it promotes a (quasi-)brittle transgranular fracture mode reducing the overall component fracture toughness. Finally, a fatigue simulation of the same chain element was conducted via finite element analysis, under a zero-based, constant amplitude load strain life analysis. For the loading conditions, the loads commonly affecting the chain element during service were applied. The simulation was based on Morrow’s law with 10⁹ cycles infinite lifetime threshold. From the results of the simulation, the stress and damage accumulation points on the chain element were identified and compared to the corresponding experimental findings. The available lifetime of the component was also estimated from the simulation. In the present paper an original industrial case study is presented. To the best of the authors’ knowledge, there was no similar study found in the relevant literature. The significance of the study is considered as quite high, since it is connected to the interruption of the production machine which costs a lot in terms of repair/replacement expenses and most important in production delays and, finally, in compromise of customer service quality and satisfaction. So, the strategy and technical content of the present investigation could stand as a valuable guide and paradigm for similar industrial failure cases, aiming to adopt and pursue a quality and excellence manufacturing model.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109406"},"PeriodicalIF":4.4,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387938","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modeling of damage interaction due to uniaxial creep and subsequent LCF pure torsional loading","authors":"Adam Tomczyk ,&nbsp;Andrzej Seweryn","doi":"10.1016/j.engfailanal.2025.109407","DOIUrl":"10.1016/j.engfailanal.2025.109407","url":null,"abstract":"<div><div>This paper presents experimental results of creep-rupture, preliminary creep and low-cycle torsional fatigue of 2024 aluminum alloy. It analyzes the effect of pre-deformation on fatigue life under pure, cyclic torsion loading conditions. Two different pre-deformation levels were considered in the creep process at 200 °C and 300 °C. A significant influence of creep pre-deformation on the cyclic properties of the tested material was obtained. This influence was characterized by, above all, improvement of fatigue life (during strain-controlled loading) of pre-deformed material in the case of large plastic strains. Two damage accumulation models were presented on the basis of these experimental test results. One makes it possible to determine the material’s damage state in the axial creep process. The other allows for predicting of fatigue life under low-cycle torsion conditions for the as-received material and material with different creep pre-deformation histories.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109407"},"PeriodicalIF":4.4,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387940","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Impact assessment of excessive and undesirable deformations in cable-to-girder connections on the structural safety of the University cable-stayed bridge in Bydgoszcz (Poland)","authors":"Bartosz Sobczyk,&nbsp;Łukasz Pyrzowski,&nbsp;Mikołaj Miśkiewicz,&nbsp;Jacek Chróścielewski,&nbsp;Krzysztof Wilde","doi":"10.1016/j.engfailanal.2025.109400","DOIUrl":"10.1016/j.engfailanal.2025.109400","url":null,"abstract":"<div><div>This article presents analyses conducted to determine the load-bearing capacity of cable-to-girder connections of a cable-stayed bridge located in Bydgoszcz, Poland. The structure was opened to traffic in 2013 and operated without incident for seven years. In 2020, excessive deformations were discovered in the zones where cables are connected to deck girders, leading the owner to close the bridge to traffic. The results of site inspections, measurements, and advanced Finite Element Method (FEM) numerical simulations are presented to comprehensively address this damage. The primary focus is on accurate prediction of the local nonlinear response of the cable-to-girder connections through numerical analyses. Validation of the numerical models is an important aspect of this paper. The conclusion drawn is that a design error was the cause of the damage. The steel plates used to build cable-to-girder connections experienced permanent plastic strains. However, this did not lead to a total loss of the structure’s load-bearing capacity. Consequently, concerns were raised regarding the necessity of closing the bridge. The deformations should have been detected earlier, but routine inspections were insufficient. It is likely that the damage had begun during cable-stay prestressing, with extreme deformations occurring during the final acceptance tests. However, these deformations did not propagate under typical service conditions. Since the bridge carries a major road, an innovative repair method is proposed to minimize the social and economic costs associated with prolonged closure.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109400"},"PeriodicalIF":4.4,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402881","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental study of fracture slip behavior in granite under different intermediate and minimum principal stresses","authors":"Zhufeng Yue ,&nbsp;Fanzhen Meng ,&nbsp;Wei Wang ,&nbsp;Dongliang Tian ,&nbsp;Qijin Cai ,&nbsp;Yuantao Wen ,&nbsp;Liming Zhang ,&nbsp;Hui Zhou","doi":"10.1016/j.engfailanal.2025.109405","DOIUrl":"10.1016/j.engfailanal.2025.109405","url":null,"abstract":"<div><div>In deep rock engineering and deep resource exploitation, faults or fractures slip and reactivation usually leads to serious dynamic geological hazards (such as seismic activities, rock bursts and landslides). However, the effect of minimum principal stress (<em>σ</em>₃) and intermediate principal stress (<em>σ</em>₂) on rough fracture slip behavior remains enigmatic. Here we present an exploratory research on slip behavior of rough granite fractures under true triaxial (<em>σ</em>₁ &gt; <em>σ</em>₂ &gt; <em>σ</em>₃) stress conditions. The results suggest that the peak strength for the fractured granite specimen increases with increasing <em>σ</em>₃, but first increases and then decreases with increasing <em>σ</em>₂. Increasing <em>σ</em>₃ restricts the slip deformation, while increasing <em>σ</em>₂ tends to first increase and then decrease the slip deformation. A three dimensional (3D) asperity which considers the contact, friction and matching relationship of fracture surfaces is used to account for the influence of <em>σ</em>₃ and <em>σ</em>₂ on strength and deformation behavior. The AE hits with larger amplitude tend to increase with increasing <em>σ</em>₃ or <em>σ</em>₂, indicating severer fault damage under higher stresses, which is consistent with the micro damage observed from SEM. The changes of wear regions and gouges with increasing <em>σ</em>₃ or <em>σ</em>₂ are in good agreement with that in peak strength and deformation along <em>σ</em>₃. The decreasing b value and increasing strain along <em>σ</em>₃ can be used as a precursor for fracture slip. Moreover, four strength criteria developed for intact rock were used to fit the results of the fractured rock, and the comparison shows that the Mogi-Coulomb criterion provides the most satisfactory results and can be used to predict the peak strength of fracture or fault failure in the applied stress regime. This study will provide new insight into a thorough understanding of shear behavior under different <em>σ</em>₃ and <em>σ</em>₂, and can also contribute to the stability assessment of fractured rock in deep underground engineering.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109405"},"PeriodicalIF":4.4,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395465","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Quantitative analysis and optimization of residual stress fields near fastener holes under combined factors","authors":"Zhiqiang Gan ,&nbsp;Lei Gan ,&nbsp;Yonghui Su ,&nbsp;Dongheng Ru ,&nbsp;Hao Wu ,&nbsp;Reza Talemi","doi":"10.1016/j.engfailanal.2025.109404","DOIUrl":"10.1016/j.engfailanal.2025.109404","url":null,"abstract":"<div><div>Residual stress surrounding the expanded hole, generated by cold expansion process, plays a pivotal role in enhancing fatigue life but is susceptible to multiple factors. Accurate comprehension of the residual stress field is the essential prerequisite for addressing the fatigue failure problem of fastener holes. In this study, 2D-Digital Image Correlation (DIC) and X-ray Diffraction (XRD) were employed to measure the residual strain and stress of hole plate subjected to split sleeve cold expansion (SSCE) under varying conditions. A 3D finite element (FE) model for tapered mandrel expansion was developed and validated against experimental results. A novel index, termed the effective residual stress, was proposed to quantitatively evaluate the residual stress field. Furthermore, the distribution characteristics of residual stress field were predicted and optimized using machine learning (ML) algorithm, considering the combined effect of the degree of cold expansion (DE), thickness of the plate, and edge distance ratio (EDR). Results indicate a nonlinear relationship between the effective residual stress and both thickness and EDR, and the influence of EDR is greater than thickness. For plates with varying thickness and EDR, the optimal DE varies from 3.5 % to 5.0 %. Specifically, when the EDR is below 3.5 and the thickness is below 10 mm, the optimal DE falls within the range of 3.5 % to 4 %.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109404"},"PeriodicalIF":4.4,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395464","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimal intensity measures for probabilistic seismic demand modeling of single-domed historical masonry buildings","authors":"Fuat Akturk ,&nbsp;Ali Yesilyurt ,&nbsp;Ferit Cakir","doi":"10.1016/j.engfailanal.2025.109378","DOIUrl":"10.1016/j.engfailanal.2025.109378","url":null,"abstract":"<div><div>This study aims to identify the optimal intensity measures for use in probabilistic seismic demand models for single-domed historical masonry buildings. Developing a probabilistic seismic demand model that describes the relationship between strong ground motion intensity measures and engineering demand parameters is critical in the performance-based earthquake engineering framework. To this end, a methodology is presented for selecting optimal intensity measures based on correlation, efficiency, practicality, proficiency, and sufficiency criteria. The 38 intensity measures commonly used in seismic vulnerability and risk assessments are categorized as follows: (i) earthquake-based, (ii) structure-based, (iii) event-based, and (iv) compound-based. Shear Stress, Normal Stress, Maximum Normal Strain, and Maximum Drift Ratio were used as engineering demand parameters to measure the structural response. In this study, the Elbistan Ulu Mosque, which was damaged after February 6, 2023, Mw7.8 and Mw7.5 Kahramanmaras earthquakes, was selected as a case study to determine the appropriate intensity parameters. For this purpose, response spectrum analyses were conducted on a 3D finite element model of the selected historical masonry structure to assess its response under seismic events. Various probabilistic seismic demand models were developed, and numerous regression analyses were performed between the engineering demand parameter and the intensity measures. After conducting thorough analysis and evaluation, spectral acceleration, spectral displacement, and modified cordova intensity were determined to be the most suitable intensity measure parameters. In addition to these optimal intensity measures, fragility curves were subsequently developed based on other relevant intensity measures, including peak ground acceleration, effective design acceleration, and A95.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109378"},"PeriodicalIF":4.4,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143388166","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental study on the failure characteristics of the loess high slope under the coupled effects of soil Consolidation, Rainfall, and evaporation","authors":"Zhuangfu Zhao ,&nbsp;Yanpeng Zhu ,&nbsp;Shuaihua Ye","doi":"10.1016/j.engfailanal.2025.109383","DOIUrl":"10.1016/j.engfailanal.2025.109383","url":null,"abstract":"<div><div>The stability of loess high-fill slopes is a crucial issue in engineering, where the presence of fissures significantly impacts slope stability. This study investigates the seepage-mechanical response and fissure evolution characteristics of loess high-fill slopes under the coupled effects of consolidation, rainfall, and evaporation through model testing. The disaster chain evolution process of the slope under these coupled effects is revealed. The results show that the development of fissures in loess high-fill slopes does not follow a directional pattern and has a uniform influence on soil properties. Under rainfall, the slope exhibits preferential flow paths, which guide the deformation and failure modes. With the development of fissures, the fill material shows a “cumulative damage effect,” leading to progressive performance degradation and continuous decline in slope stability. This study enriches the theoretical framework for stability analysis of high-fill fissured slopes and provides guidance for disaster prevention and mitigation in loess regions.</div></div>","PeriodicalId":11677,"journal":{"name":"Engineering Failure Analysis","volume":"171 ","pages":"Article 109383"},"PeriodicalIF":4.4,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376688","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}