Effect of the sector radius of a workpiece-deforming tool on the stress-strain state in the contact zone with a cylindrical surface

This paper aims to determine the effect of the sector radius of a workpiece-deforming tool on the stress-strain state in the center of elastoplastic deformation and residual stresses in the hardened zone of the surface layer of cylindrical workpieces. A mathematical model of local loading was constructed using the finite element method and AN-SYS software. This model was used to determine the values of temporary and residual stresses and deformations, as well as the depth of plastic zone, depending on the sector radius of the working tool. The simulation results showed that, under the same loading of a cylindrical surface, working tools with different sector radii create different maximum tempo-rary and residual stresses. An assessment of the stress state was carried out for situations when the surface layer of a product is treated by workpiece-deforming tools with a different shape of the working edge. It was shown that, compared to a flat tool, a decrease in the radius of the working sector from 125 to 25 mm leads to an increase in the maximum temporary and residual stresses by 1.2–1.5 times, while the plastic zone depth increases by 1.5–2.4 times. The use of a working tool with a flat surface for hardening a cylindrical workpiece ensures minimal temporary residual stresses, com-pared to those produced by a working tool with a curved surface. A decrease in the radius of the working sector leads to an increase in temporary residual stresses by 2–7%. The plastic zone depth ranges from 1.65 to 2.55 mm when chang-ing the sector radius of the working tool.

Numerical Simulation of Mechanical Characteristics of Roadway Surrounding Rock under Dynamic and Static Loading

Mechanical characteristics of roadway surrounding rock under different stress wave disturbances are the key to design roadway supporting scheme. In this study, the 2802 transportation roadway in Zhangcun Coal Mine is selected as the engineering background. The distribution of stress, displacement, and plastic zone in surrounding rock under the impact of different stress waves is studied. Results show that the stress and displacement of the roof, floor, and coal walls present fluctuating change with time during the stress wave loading process. With the increase of disturbing intensity of stress wave, the resistance ability for stress wave disturbance of the roof is lower than that of the floor, while the resistance ability of two sides is the same. The volume of plastic zone in roadway surrounding rock was calculated by the self-compiled FISH code. The relationship between the plastic zone volume and the stress wave disturbing intensity in different states is explored. The cubic polynomial relationship between the volume and the disturbing intensity in the state of shear_past and tension_past is obtained. Under the simulated condition, the disturbing intensity of stress wave has the greatest influence on the increase of shear_past volume when it equals 11 MPa. While the disturbing intensity of stress wave has the greatest influence on the increase of tension_past volume, it equals 7 MPa. Meanwhile, the relation between stress wave disturbing intensity and surrounding rock stress and displacement is obtained respectively. The achievements provide a theoretical base for roadway surrounding rock support under dynamic and static loading.

Optimal Support Solution for a Soft Rock Roadway Based on the Drucker–Prager Yield Criteria

Through theoretical calculation, the stress and deformation of surrounding rock can be analyzed, providing guidance for the support design and optimization of soft rock roadways. In this paper, theoretical solutions for both the optimal support pressure and the allowable maximum displacement of surrounding rock are derived from the Drucker–Prager (DP) yield criteria and the steady creep criterion expressed by the third invariant of deviator stress. The DP criterion with different parameters is compared and analyzed with an engineering example. Then, based on the calculation results the effects of long-term strength, cohesion, and internal friction angle of soft rock on the maximum plastic zone radius and allowable maximum displacement of roadway are discussed. The results show that the optimal support solution of soft rock roadways based on the DP criteria can not only reasonably reflect the intermediate principal stress but can also be used to compare and discuss the influence of different DP criteria on the calculation results. The higher the long-term strength of the rock surrounding a roadway is, the smaller the optimal support force is and the larger the allowable maximum displacement is. When the calculated long-term strength of soft rock can ensure that the deformation of the roadway does not exceed the allowable maximum displacement, the roadway can maintain long-term stability without support. With an increase in the cohesion or internal friction angle of soft rock, the radius of the plastic zone decreases gradually and the allowable maximum displacement is reduced by degrees. The use of grouting and other means to improve the strength of surrounding rock can effectively reduce the roadway deformation and save support costs. This new theoretical solution can consider different intermediate principal stress effects and different DP strength criteria, enabling the parameters to become easier to determine. It has a wider range of applications, and the calculation results better demonstrate the strength potential of the surrounding rock.

Simulation of the interaction of plastic zone dislocations with the grain boundary at brittle-plastic transition temperatures in molybdenum

The (DD) method was used to model the formation of the plastic zone of the top of the cracks in polycrystalline molybdenum. Special attention was paid to take into account the interaction of dislocations in the plastic zone with grain boundaries. Structural sensitivity of fracture toughness was analyzed under brittle-ductile condition. Simulations were performed for a range of grain sizes from 400 to 100 μm, at which a sudden increase in fracture toughness with a decrease of grain size was experimentally shown. We calculated the value of K1c taking into account the shielding action of dislocations. The position of all dislocations in the plastic zone at fracture moment was calculated. Based on these data, we obtained the dependences of dislocation density on the distance from the crack tip thereby confirming significant influence of the grain boundaries on plastic zone formation. At large grain sizes, when the plastic zone does not touch the boundary, the distribution of dislocations remained unchanged. As grains reduce their size to size of the plastic zone, they start formating a dislocation pile – up near the boundaries. Dislocations on plastic zone move slightly toward the crack tip, but the density of dislocations in the middle of the grain remains unchanged, and fracture toughness remains almost unchanged. Further reduction of the grain size leads to the Frank-Reed source activation on the grain boundary Forming dislocation pile-up of the neighbor grains. Its stress concentration acts on dislocations of the first grain and causes redistribution of plastic zone dislocations. If the reduction in grain size is not enough to form a strong pile-up, density of dislocations on plastic zone increases slightly and crack resistance increases a few percent. Further reduction of grains promotes strong pile-up, dislocations move to crack tip, and its density on plastic zone increases. Crack is shielded and fracture toughness increases sharply. The calculation showed that the fracture toughness jump is observed at grain sizes of 100—150 μm, in good agreement with the experiment. Keywords: dislocation dynamics simulation, molybdenum, fracture toughness, grain size, plastic zone, brittle-ductile transition.

Surrounding Rock Control Technology When the Longwall Face Crosses Abandoned Roadways: A Case Study

When a working face is crossing the abandoned roadways, problems such as roof subsidence, rock fracture, and instability will occur, resulting in widespread roof fall and rib spalling, which seriously affect safe and efficient mining on the working face. In this paper, the no. 23 coal pillar working face of Juji coal mine is taken as the engineering background, a mechanical model of crossing the abandoned roadways is constructed aimed at the problem of the working face crossing the abandoned roadway group, the collapse of the abandoned roadway roof is analyzed, a scheme of crossing the abandoned roadways is designed, and the development law of the stress and plastic zone after the reinforcement scheme is stimulated and analyzed. The results show that when the working face advances to the abandoned roadway, key block B crosses the abandoned roadway and the solid coal to form a “cross-roadway long key block.” It is calculated that the minimum support resistance required for the abandoned roadway is 6700 kN. Based on the results of numerical comparison, it is concluded that filling wood pile when the working face passes through the roof abandoned roadway and adding anchor cables for reinforcement support when the working face crosses the coal seam abandoned roadway effectively reduce the stress concentration of surrounding rocks, decrease the development of the plastic zone, and achieve safe and efficient mining when the working face crosses the abandoned roadways.

Optimization of the Plastic Area of a Borehole Based on the Gas Extraction Effect and Its Engineering Application

Gas extraction is most commonly used to control gas disasters in coal mines. The distribution of the plastic zone around a borehole and the sealing quality are key factors affecting gas extraction. In this paper, the plastic zone was simulated by COMSOL, and a theoretical equation of the plastic zone radius was derived. In addition, an antispray hole equipment and the “two plugging and one injection” sealing technology were proposed. The results show that a larger borehole pore size corresponds to a larger plastic zone and larger range of pressure relief of the borehole. The error between the calculated and simulated plastic zone radii is within 1%, and the modified equation is applicable to Puxi mine. The loss and harm caused by borehole spraying are reduced by applying antispray hole equipment. By applying the “two plugging and one injection” sealing technology and phosphogypsum-based self-produced gas expansion paste material to block the borehole, the sealing quality is improved and an accurate gas mixing flow, pure flow, and concentration were obtained. As the plastic zone enlarges, the gas extraction flow gradually increases with, but the relative variation of flow first increases and subsequently decreases. Considering the safety and economy of construction, the optimal radius of the plastic zone is 64.9 mm.

Application of the method of dimensional analysis in laser-shock-wave processing of titanium alloys with shape memory

The processes of laser-shock-wave processing of NiTi alloys with shape memory effect are investigated by the methods of dimensional analysis and finite element modeling. The dependences of the depth of the plastic zone on the peak pressure in the shock wave and the duration of the laser pulse are obtained at different peak pressures. Keywords: shape memory alloys, laser-shock-wave processing, dimensional analysis, residual stresses, plastic zone depth. [email protected]