Analysis of multiple failure behaviors of steering knuckle ball hinge of multi-axle heavy vehicle

The ball hinge is a key component of the vehicle chassis that connects the steering knuckle and the control arm. The study analyzed the multiple failure behaviors of the chassis ball hinge. Firstly, according to the macroscopic failure characteristics of the ball hinge, the fault tree analysis method was adopted to identify the possible cause of the failure. Then, the axial load and radial load on the ball joint were obtained by simulating the force of the vehicle under the typical extreme conditions. The stress distribution of the ball pin was obtained by finite element analysis of the ball joint. The calculation results are consistent with the fatigue crack position of the ball hinge. Finally, the macro morphology and microstructure of the ball joint seat, ball bowl, dust cover and other parts matched with the ball hinge were analyzed to further verify the failure mode of the ball hinge. The results showed that the dust cover of the ball hinge was firstly aged and cracked, and the external dust and particles enter into the friction contact area of the ball hinge, which caused the ball pin and ball bowl to be stuck. During the operating of the vehicle, the ball pin undergoes unidirectional bending fatigue fracture in the stress concentration area at the root of the conical surface.

Multiscale modeling of damage and fracture in freeze-thawed shotcrete

Degradation of fracture resistance, which is a phenomenon encountered in shotcrete as exposed to the cold environment, can lead to structural failure. Microstructural damage induced by freeze-thaw (F-T) cycles serves as the presage to macroscopic failure processes. To reveal the fundamental mechanisms of degradation, it is crucial to characterize and model the F-T damage in multiscales for the heterogeneous nature of shotcrete. In this paper, X-ray micro-computed tomography (micro-CT) is employed to describe the F-T damage in microscale and mesoscale shotcrete. Changes of the modulus of elasticity in cement paste and interfacial transition zone are analyzed using the cloud map obtained from the nanoindentation test. Micro-CT images capture the microstructural geometry, such as microcracks, aggregates, pores, and cement paste. Subsequently, microstructure-based finite-element modeling is developed to simulate the overall mechanical properties and fracture behavior of freeze-thawed shotcrete. The effect of F-T-induced damage is investigated on the three-phase fracture processes in terms of load versus deflection curves and cracking paths of shotcrete beams. The modeling results for damage and fracture are validated against the experimental data using the three-point bending tests of shotcrete beams.

Numerical modelling of the crack-pore interaction and damage evolution behaviour of rocklike materials with pre-existing cracks and pores

The combined effect of pre-existing cracks and pores on the damage evolution behaviour and mechanical properties of rocklike materials under uniaxial compression was numerically studied. Simulations of cracks and pores alone showed that increasing crack length and pore diameter decrease uniaxial compressive strength (UCS) and elastic modulus. Subsequent simulations considered two types of combinations of pre-existing cracks and pores – two cracks either side of a centric pore, and two pores either side of a centric crack – and the distance between cracks and pores was changed. In the case of two cracks at either side of the pore, UCS increased only slightly when the distance between the cracks and pore was increased. This was attributed to the more profound effect of the presence of the pore on UCS, and was confirmed by the progressive crack development characteristics and the major principal stress distribution patterns, which showed that the cracks initiated from the tips of the two pre-existing cracks made little or no contribution to the ultimate macroscopic failure. In contrast, models with two pores at either side of a centric crack showed a marked dependency of UCS on the distance between the pores and the crack. Cracks propagating from pre-existing pores made a greater contribution to the ultimate macroscopic failure when the pores were close to the centric crack and the effect gradually diminished with increasing space between pre-existing pores and the centric crack. Major principal stress distributions showed an asymmetric mobilisation of compressive stresses at the right and left sides of the two pores, favouring macroscopic shear failure when they were close to the centric crack which had led to a lower UCS. Overall, this study presents some critical insights into crack-pore interaction behaviour and the resulting mechanical response of rocklike materials to assist with the design of rock structures.

Mode-Independent and Mode-Interactive Failure Criteria for Unidirectional Composites Based on Strain Energy Density

The strain energy released plays a crucial role in generating macroscopic failure in unidirectional (UD) composites. This paper proposes two new strain energy-based failure criteria, regarding fiber-dominated and matrix-dominated failure mode as independent and interactive, respectively. The failure expression is formulated based on rigorous mathematical deducing, accompanied by physical interpretation. Based on the lack of experimentally feasible multi-axial strengths, a predefined assumption of infinite strength under bi-axial and tri-axial compressive stress provides the possibility for determining all coefficients only by using conventional uniaxial strengths. The failure envelopes predicted by the proposed criteria have been validated against experimental results under biaxial, off-axis and tri-axial loading cases. A better agreement with physical reality was achieved by the failure mode-interactive criterion, suggesting a wide range of applicability.

An Experimental Study of the Failure Mode of ZnO Varistors Under Multiple Lightning Strokes

In this study, in order to explore the failure mode of ZnO varistors under multiple lightning strokes, a five-pulse 8/20 μs nominal lightning current with pulse intervals of 50 ms was applied to ZnO varistors. Scanning electron microscopy (SEM) and X-ray diffractometry (XRD) were used to analyze the microstructure of the material. The failure processes of ZnO varistors caused by multiple lightning impulse currents were described. The performance changes of ZnO varistors after multiple lightning impulses were analyzed from both macro and micro perspectives. According to the results of this study’s experiments, the macroscopic failure mode of ZnO varistors after multiple lightning impulses involved the rapid deterioration of the electrical parameters with the increase of the number of impulse groups, until destruction occurred by side-corner cracking. The microstructural examination indicated that, after the multiple lightning strokes, the proportion of Bi in the crystal phases was altered, the grain size of the ZnO varistors became smaller, and the white intergranular phase (Bi-rich grain boundary layer) increased significantly. The failure mechanism was thermal damage and grain boundary structure damage caused by temperature gradient thermal stress, generated by multiple lightning currents.

An Experimental Study of the Failure Mode of ZnO Varistors under Multiple Lightning Stroke

In this study, in order to explore the failure mode of ZnO varistors under multiple lightning stroke, a 5-pulse 8/20 μs nominal lightning current with pulse intervals of 50 ms was applied to the ZnO varistors. Scanning electron microscopy (SEM) and X-ray diffractometry (XRD) were used to analyze the microstructure of the material. The failure processes of ZnO varistors caused by multiple lightning impulse current were described. The performance changes of ZnO varistors after multiple lightning impulses were analyzed from macro and micro perspectives. According to the results of this study’s experiments, the macroscopic failure mode of the ZnO varistors after multiple lightning impulse was that the electrical parameters deteriorate rapidly with the increase of the number of impulse groups, and finally destroyed by side-corner cracking. The microstructural examination indicated that after the multiple lightning strokes, the proportion of Bi in the several crystal phases had been converted, the grain size of ZnO varistors became smaller, and the white intergranular phase (Bi-rich grain boundary layer) increased significantly. The failure mechanism was thermal damage and grain boundary structure damage caused by temperature gradient thermal stress generated by multiple lightning current.