Assessment of a Rock Pillar Failure by Using Change Detection Analysis and FEM Modelling

In this paper, various methods have been used to control and evaluate engineering difficulties in mining accurately. Different unstable scenarios occurring at the surfaces of underground mine walls, have been identified by comparing 3D terrestrial laser scanning surveys and subsequent point cloud 3D analysis. These techniques, combined with a change detection analysis approach and the integration of rock mechanics’ modelling, represent an asset for the assessment and management of the risk in mining. The change detection analysis can be used as control of mining and industrial processes as well as to identify valid model scenarios for establishing possible failure causes. A pillar spalling failure has been identified in an Italian underground marble quarry and this topic represents the basis of the present paper. A Finite-Element Method was used to verify the occurrence of relatively high-stress concentrations in the pillar. The FEM modelling revealed that stresses in the proximity of the pillar may have sufficient magnitude to induce cracks growth and spalling failure.

Effects of Tooth Surface Crack Propagation on Meshing Stiffness and Vibration Characteristic of Spur Gear System

Tooth surface cracks are considered as the early stage of the development of tooth surface spalling failure. Understanding the excitation mechanism of surface cracks has a great significance in the early diagnosis of spalling faults. However, there are few studies on the dynamic modelling of surface cracks, and the influence mechanism of surface cracking on the dynamic characteristics of a gear system is also not yet clear during its propagation process. Thus, an analytical calculation model of the meshing stiffness of gear with tooth surface crack is developed. Then, a dynamic model of a spur gear system with six degrees of freedom (DOF) is established based on the proposed surface crack calculation model. The effects of surface crack propagation on the meshing stiffness and dynamic characteristics of gear system are investigated. The results show that the side frequencies of dynamic transmission error (DTE) are more sensitive than those of the acceleration responses during the surface crack propagation, which is more favorable to the surface crack fault diagnosis. Compared to the traditional spalling fault model, the proposed model can accurately characterize the dynamic characteristics of a gear system with the early spalling defect.

Failure Behaviour of Sandstone with a Preexisting Joint under Stepped Excavation

Much geotechnical construction needs to be carried out under the condition of stepped excavation. However, there is still a lack of research on crack coalescence and failure modes of jointed rock mass under stepped excavation conditions. In order to simulate the stepped excavation test of the real project, the polylactic acid (PLA) material is selected as the filler for the excavation area. The stepped excavation tests are performed on sandstone specimens containing a preexisting joint under different normal load conditions. The dynamic stepped excavation of simulating excavate rock engineering is realised. The constant normal loads during the excavation process are determined to be 80 kN and 100 kN. The influence of the joint inclination on the failure characteristics of the excavation process is analysed. Four typical failure modes are summarised: (a) Mode I: crack coalescence of tensile failure; (b) Mode II: crack coalescence of mixed failure; (c) Mode III: without crack coalescence of mixed failure; (d) Mode IV: without crack coalescence of shear failure. Furthermore, the failure characteristics of the area above the excavation hole and the preexisting joint are analysed. The results show that there are three failure modes: (a) Type I: spalling failure; (b) Type II: shear slip failure; (c) Type III: shear slip and spalling mixed failure.

Microstructure and Wear Properties of Micro Arc Oxidation Ceramic Coatings

The interaction effect of micro arc oxidation (MAO) parameters on the microstructure and wear properties was investigated. The results showed that the electric current and oxidation time significantly influenced the thickness and grinding crack width of the ceramic coatings within the range of the selected parameters, and the interaction effect of the electrical parameters was not obvious. The surface morphology, cross-section morphology, and element distribution of the coatings were observed using scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The results showed that ceramic coatings with γ-Al2O3 and α-Al2O3 formed, which enhanced the coating performance. After that, the microhardness and wear resistance were tested. Under the optimal process, the microhardness of a coating section was up to 1200 HV0.1, and the friction coefficient was just 0.3. When wear occurred, the volcanic microstructures experienced extrusion and deformation, and then peeled off under shear stress, which led to the formation of a grinding crack. The main failure modes of the micro arc oxidation coatings were abrasive wear and spalling failure.

A numerical study of the contact and vibration characteristics of a roller bearing with a surface crack

Roller bearings are key parts in different machineries. As one of the major incipient failure models in the bearings, the surface crack will be enlarged to be a large spalling failure. Moreover, the abrupt changes in the contact characteristics caused by the crack zone would produce unacceptable impulses, which can affect the bearing vibrations. Thus, a study of the contact characteristics and vibrations of the bearings including the surface crack could be conducive for the incipient fault monitoring methods. To overcome this issue, a finite element model is proposed to obtain the influences of the depth and slope angle of a surface crack on the contact characteristics in a roller bearing. The relationships between the contact characteristics (contact deformation, width and stiffness) and crack sizes (depth and slope angle) are established. To study the influences of the surface crack sizes on the bearing vibrations, a dynamic model of the roller bearing considering the surface crack is also proposed. An experiment is introduced to verify the proposed method. It seems that the crack depth and slope angle can greatly affect the contact and vibration characteristics of the bearing. This study provides a helpful numerical approach for understanding the contact and vibration characteristics of roller bearings with various surface cracks.

Evaluation of contact fatigue risk of a carburized gear considering gradients of mechanical properties

Carburized gears are widely used in geared machines such as wind turbines. Contact fatigue problems occur in engineering practice, reducing reliabilities of machines. Contact fatigue failures are related to many factors, such as gradients of mechanical properties of the hardening layer. In this work, an elastic-plastic contact model of a carburized gear is developed based on the finite element method to evaluate contact fatigue failure risk, considering variations in hardness and strength. The Dang Van multiaxial equivalent stress is calculated via Python coding within the Abaqus framework. The gradient of yield strength along the depth from case to core is considered. The concept of local material fatigue failure risk is defined to evaluate the probability of pitting failure. The effects of design factors, such as the case hardening depth (CHD), surface hardness, and contact pressure on fatigue failure risk, are studied. As the CHD increases or the surface hardness decreases, the risk of deep spalling failure reduces. The increase in surface hardness leads to a decreased risk of pitting failure, while the variation in CHD hardly affects the pitting failure risk.