Numerical simulation of residual stress field in green power metallurgy compacts by modified Drucker-Prager Cap model

Compaction process simulation and residual stress prediction of green PM compact were carried out with elasto-plastic 3D FEA based on the modified Drueker-Prager Cap model in Abaqus. The model parameters of the investigated powder Distaloy AE were determined as functions of relative density through typical mechanical property tests of powder. The model was implemented as a user subroutine USDFLD. Single sided compaction of a d20 ram^5 mm disk green compact of Distaloy AE was simulated, and the residual stress of the disk after ejection was predicted with FEA. The FEA results of the compaction process and the residual stress of the disk show good agreement with compaction experiments and X-ray diffraction measurements, which validates the model and its parameters. The results indicate that the compressive residual stresses exist mainly in a thin layer on the side surface, but the residual stresses are very small on the top and bottom surfaces.

Measurement of Residual Stress Field of Hardfacing Metal with RE Oxide and Its Numerical Simulation

The temperature and residual stress fields of a medium-high carbon steel, welded by a cracking resistance electrode with rare earth (RE) oxide, were measured by thermo-vision analyzer and X-ray stress analyzer respectively. Meanwhile, the martensitic transformation temperatures of matrix, hard-face welding (hardfacing) metal welded by conventional hardfacing electrode and that welded by cracking resistance electrode with RE oxide were determined. According to the experimental data and the thermo-physical, mechanical parameters of materials, finite element method (FEM) of temperature and stress fields was established. In this FEM, the effect of martensitic transformation on residual stress of hardfacing metal of medium-high carbon steel was taken into account. The results show that, by adding RE oxide in the coat of hardfacing electrode, the martensitic transformation temperature can be decreased, so that the residual tensile stress on the dangerous position can be decreased. Therefore, the cracking resistance of hardfacing metal can be improved.

Evolution of residual stress field in 6N01 aluminum alloy friction stir welding joint

Based on the characteristics of friction stir welding( FSW) and Coulomb friction work theory,the residual stresses field of FSW joints of 6 N01 aluminum alloy( T5),which was used in high speed train,were calculated by using the ANSYS finite element software. During the FEM calculation,the dual heat source models namely the body heat source and surface heat source were used to explore the evolution law of the welding process to the residual stress field. The method of ultrasonic residual stress detecting was used to investigate the residual stresses field of the 6 N01 aluminum alloy FSW joints. The results show that the steady-state temperature of 6 N01 aluminum alloy during FSW is about 550 ℃,and the temperature mutates at the beginning and at end of welding. The longitudinal residual stress σ_x is the main stress,which fluctuates in the range of-25 to 242 MPa. Moreover,the stress in the range of shaft shoulder is tensile stress that the maximum tensile stress is 242 MPa,and the stress in the outside of shaft shoulder is compressive stress that the maximum compressive stress is 25 MPa. The distribution of the tensile stress in the welding nugget zone( WNZ) is obviously bimodal,and the residual stress on the advancing side is higher than that on the retreating side. With the increasing of the welding speed,the maximum temperature decreased and the maximum residual stress decreased when the pin-wheel speed kept constant. With the increasing of the pin-wheel speed,the maximum temperature of the joint increased and the maximum residual stress increased when the welding speed was constant. The experimental results were in good agreement with the finite element results.

Shakedown Criterion Employing Actual Residual Stress Field and Its Application in Numerical Shakedown Analysis

Construction of the static admissible residual stress field and searching the optimal field are key tasks in the shakedown analysis methods applying the static theorem. These methods always meet dimension obstacles when dealing with complex problems. In this paper, a novel shakedown criterion is proposed employing actual residual stress field based on the static shakedown theorem. The actual residual stress field used here is produced under a specified load path, which is a sequence of proportional loading and unloading from zero to all the vertices of the given load domain. This ensures that the shakedown behavior in the whole load domain can be determined based on the theorem proposed by K6nig. The shakedown criterion is then implemented in numerical shakedown analysis, The actual residual stress fields are calculated by incremental finite element elastic-plastic analysis technique for finite deformation under the specified load path with different load levels. The shakedown behavior and the shakedown limit load are determined according to the proposed criterion. The validation of the criterion is performed by a benchmark shakedown example, which is a square plate with a central hole under biaxial loading. The results are consistent with existing results in the literatures and are validated by full cyclic elastic-plastic finite element analysis. The numerical shakedown analysis applying the proposed criterion avoids processing dimension obstacles and performing full cyclic elastic-plastic analysis under arbitrary load paths which should be accounted for appearing. The effect of material model and geometric changes on shakedown behavior can he considered conveniently.

Nondestructive Testing and Characterization of Residual Stress Field Using an Ultrasonic Method

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel（12%C） as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave（LCR wave） is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

Modeling of Temperature and Residual Stress Fields Resulting from Impacting Process of a Molten Ni Particle onto a Flat Substrate

Several effective numerical techniques,based on a finite element analysis,have been developed and computed independently.Results are presented describing the impacting process,and the subsequent temperature and residual stress fields of a molten nickel particle impacting onto a flat substrate.Problems of this type,especially the prediction of the thermal residual stresses,are of major practical interest in thermal spray operations as a pioneering approach.

CALCULATION OF RESIDUAL STRESS FIELD IN LASER TRANSFORMATION HARDENED MoCu NODULAR IRON

In this paper,a thermal elastic-plastic 2-D finite element model of stress generation during laser transformation hardening process was developed. In this model, the mechanical properties of the material, Young's modules E, Poisson's ratio v, yield limit s, and thermal expansion coefficient α, are all change with temperature. The equivalent expansion method was used to deal with the problem with phase transformation. Based on this model, a program to calculate the residual stress field was developed using FORTRAN language. The residual stress fields in CO2 laser transformation hardened MoCu nodular iron were calculated. The calculated results showed that in the transformation hardened zone, the residual stress state is compress,whereas adjacent to this zone the residual stress state is tensile, and there is a tensile stress peak close to the transformation hardened zone. To verify this model, the residual stress fields were measured using X-ray diffraction method. The calculated results of residual stress fields are in good agreement with the experimental results.

Effect of Modulus Heterogeneity on the Equilibrium Shape and Stress Field ofαPrecipitate in Ti-6Al-4V

For media with inclusions(e.g.,precipitates,voids,reinforcements,and others),the difference in lattice parameter and the elastic modulus between the matrix and inclusions cause stress concentration at the interfaces.These stress fields depend on the inclusions’size,shape,and distribution and will respond instantly to the evolving microstructure.This study develops a phase-field model concerningmodulus heterogeneity.The effect of modulus heterogeneity on the growth process and equilibrium state of theαplate in Ti-6Al-4V during precipitation is evaluated.Theαprecipitate exhibits strong anisotropy in shape upon cooling due to the interplay of the elastic strain and interfacial energy.The calculated orientation of the habit plane using the homogeneous modulus ofαphase shows the smallest deviation fromthat of the habit plane observed in the experiment,compared to the case where the homogeneous modulus ofβphase is adopted.In addition,the equilibrium volume ofαphase within the systemusing homogeneousβmodulus exhibits the largest dependency on the applied stresses.The stress fields across theα/βinterface are further calculated under the assumption of modulus heterogeneity and compared to those using homogeneous modulus of eitherαorβphase.This study provides an essential theoretical basis for developing mechanics models concerning systems with heterogeneous structures.

Support design method for deep soft-rock tunnels in non-hydrostatic high in-situ stress field

Due to the long-term plate tectonic movements in southwestern China,the in-situ stress field in deep formations is complex.When passing through deep soft-rock mass under non-hydrostatic high in-situ stress field,tunnels will suffer serious asymmetric deformation.There is no available support design method for tunnels under such a situation in existing studies to clarify the support time and support stiffness.This study first analyzed the mechanical behavior of tunnels in non-hydrostatic in-situ stress field and derived the theoretical equations of the ground squeezing curve(GSC)and ground loosening curve(GLC).Then,based on the convergence confinement theory,the support design method of deep soft-rock tunnels under non-hydrostatic high in-situ stress field was established considering both squeezing and loosening pressures.In addition,this method can provide the clear support time and support stiffness of the second layer of initial support.The proposed design method was applied to the Wanhe tunnel of the China-Laos railway in China.Monitoring data indicated that the optimal support scheme had a good effect on controlling the tunnel deformation in non-hydrostatic high in-situ stress field.Field applications showed that the secondary lining could be constructed properly.

Stress corrosion cracking behavior of buried oil and gas pipeline steel under the coexistence of magnetic field and sulfate-reducing bacteria

Magnetic field and microorganisms are important factors influencing the stress corrosion cracking(SCC)of buried oil and gas pipelines. Once SCC occurs in buried pipelines, it will cause serious hazards to the soil environment. The SCC behavior of X80 pipeline steel under the magnetic field and sulfate-reducing bacteria(SRB) environment was investigated by immersion tests, electrochemical tests, and slow strain rate tensile(SSRT) tests. The results showed that the corrosion and SCC sensitivity of X80 steel decreased with increasing the magnetic field strength in the sterile environment. The SCC sensitivity was higher in the biotic environment inoculated with SRB, but it also decreased with increasing magnetic field strength, which was due to the magnetic field reduces microbial activity and promotes the formation of dense film layer. This work provided theoretical guidance on the prevention of SCC in pipeline steel under magnetic field and SRB coexistence.

The 2023 Turkey earthquake doublet: Earthquake relocation, seismic tomography, and stress field inversion

On February 6,2023,two earthquakes with magnitudes of M_(W) 7.8 and M_(W) 7.5 struck southeastern Turkey,causing significant casualties and economic losses.These seismic events occurred along the East Anatolian Fault Zone,a convergent boundary between the Arabian Plate and the Anatolian Subplate.In this study,we analyze the M_(W) 7.8 and M_(W) 7.5 earthquakes by comparing their aftershock relocations,tomographic images,and stress field inversions.The earthquakes were localized in the upper crust and exhibited steep dip angles.Furthermore,the aftershocks occurred either close to the boundaries of low and high P-wave velocity anomaly zones or within the low P-wave velocity anomaly zones.The East Anatolia Fault,associated with the M_(W) 7.8 earthquake,and the SürgüFault,related to the M_(W) 7.5 earthquake,predominantly experienced shear stress.However,their western sections experienced a combination of strike-slip and tensile stresses in addition to shear stress.The ruptures of the M_(W) 7.8 and M_(W) 7.5 earthquakes appear to have bridged a seismic gap that had seen sparse seismicity over the past 200 years prior to the 2023 Turkey earthquake sequence.

A novel indirect optical method for rock stress measurement using microdeformation field analysis

Stress measurement plays a crucial role in geomechanics and rock engineering,especially for the design and construction of large-scale rock projects.This paper presents a novel method,based on the traditional stress relief approach,for indirectly measuring rock stress using optical techniques.The proposed method allows for the acquisition of full-field strain evolution on the borehole’s inner wall before and after disturbance,facilitating the determination of three-dimensional(3D)stress information at multiple points within a single borehole.The study focuses on presenting the method’s theoretical framework,laboratory validation results,and equipment design conception.The theoretical framework comprises three key components:the optical imaging method of the borehole wall,the digital image correlation(DIC)method,and the stress calculation procedure.Laboratory validation tests investigate strain field distribution on the borehole wall under varying stress conditions,with stress results derived from DIC strain data.Remarkably,the optical method demonstrates better measurement accuracy during the unloading stage compared to conventional strain gauge methods.At relatively high stress levels,the optical method demonstrates a relative error of less than 7%and an absolute error within 0.5 MPa.Furthermore,a comparative analysis between the optical method and the conventional contact resistance strain gauge method highlights the optical method’s enhanced accuracy and stability,particularly during the unloading stage.The proposed optical stress measurement device represents a pioneering effort in the application of DIC technology to rock engineering,highlighting its potential to advance stress measurement techniques in the field.

Impact of well placement and flow rate on production efficiency and stress field in the fractured geothermal reservoirs

Geothermal energy has gained wide attention as a renewable alternative for mitigating greenhouse gas emissions.The advancements in enhanced geothermal system technology have enabled the exploitation of previously inaccessible geothermal resources.However,the extraction of geothermal energy from deep reservoirs poses many challenges due to high‐temperature and high‐geostress conditions.These factors can significantly impact the surrounding rock and its fracture formation.A comprehensive understanding of the thermal–hydraulic–mechanical(THM)coupling effect is crucial to the safe and efficient exploitation of geothermal resources.This study presented a THM coupling numerical model for the geothermal reservoir of the Yangbajing geothermal system.This proposed model investigated the geothermal exploitation performance and the stress distribution within the reservoir under various combinations of geothermal wells and mass flow rates.The geothermal system performance was evaluated by the criteria of outlet temperature and geothermal productivity.The results indicate that the longer distance between wells can increase the outlet temperature of production wells and improve extraction efficiency in the short term.In contrast,the shorter distance between wells can reduce the heat exchange area and thus mitigate the impact on the reservoir stress.A larger mass flow rate is conducive to the production capacity enhancement of the geothermal system and,in turn causes a wider range of stress disturbance.These findings provide valuable insights into the optimization of geothermal energy extraction while considering reservoir safety and long‐term sustainability.This study deepens the understanding of the THM coupling effects in geothermal systems and provides an efficient and environmentally friendly strategy for a geothermal energy system.

Simulation Analysis of Stress Field of Walnut Shell Composite Powder in Laser Additive Manufacturing Forming

A calculation model of stress field in laser additive manufacturing of walnut shell composite powder(walnut shell/Co-PES powder)was established.The DFLUX subroutine was used to implement the moveable application of a double ellipsoid heat source by considering the mechanical properties varying with temperature.The stress field was simulated by the sequential coupling method,and the experimental results were in good accordance with the simulation results.In addition,the distribution and variation of stress and strain field were obtained in the process of laser additive manufacturing of walnut shell composite powder.The displacement of laser additive manufacturing walnut shell composite parts gradually decreased with increasing preheating temperature,decreasing laser power and increasing scanning speed.During the cooling process,the displacement of laser additive manufacturing of walnut shell composite parts gradually increased with the increasing preheating temperature,decreasing scanning speed and increasing laser power.

Residual elastic stress strain field and geometrically necessary dislocation density distribution around nano-indentation in TA15 titanium alloy

Nanoindentation and high resolution electron backscatter diffraction（EBSD） were combined to examine the elastic modulus and hardness of α and β phases,anisotropy in residual elastic stress strain fields and distributions of geometrically necessary dislocation（GND） density around the indentations within TA15 titanium alloy.The nano-indention tests were conducted on α and β phases,respectively.The residual stress strain fields surrounding the indentation were calculated through crosscorrelation method from recorded patterns.The GND density distribution around the indentation was calculated based on the strain gradient theories to reveal the micro-mechanism of plastic deformation.The results indicate that the elastic modulus and hardness for α p hase are 129.05 GPas and 6.44 GPa,while for β phase,their values are 109.80 GPa and 4.29 GPa,respectively.The residual Mises stress distribution around the indentation is relatively heterogeneous and significantly influenced by neighboring soft β phase.The region with low residual stress around the indentation is accompanied with markedly high a type and prismatic-GND density.

Effect of hydraulic fracturing induced stress field on weak surface activation during unconventional reservoir development

Unconventional reservoirs usually contain many weak surfaces such as faults,laminae and natural fractures,and effective activation and utilization of these weak surfaces in reservoirs can significantly improve the extraction effect.In hydraulic fracturing,when the artificial fracture approaches the natural fracture,the natural fracture would be influenced by both the original in-situ stress field and the hydraulic fracturing-induced stress field.In this paper,the hydraulic fracturing-induced stress field is calculated based on the relative position of hydraulic fracture and natural fracture,the original in-situ stress,the net pressure inside the hydraulic fracture and the pore pressure of the formation.Furthermore,the stability model of the natural fracture is established by combining the Mohr-Coulomb rupture criterion,and extensive parametric studies are conducted to explore the impact of each parameter on the stability of the natural fracture.The validity of the proposed model is verified by comparing with the reservoir characteristics and fracturing process of the X-well 150e155 formation in the Songliao Basin.It is found that the stress field induced by the hydraulic fracture inhibits the activation of the natural fracture after the artificial fracture crossed the natural fracture.Therefore,for similar reservoirs as X-well 150e155,it is suggested to connect natural fractures with hydraulic fractures first and then activate natural fractures which can effectively utilize the natural fractures and form a complex fracture network.

Tensile Fractures and in situ Stress Measurement Data Constraints on Cretaceous-Present Tectonic Stress Field Evolution of the Tanlu Fault Zone in Shandong Province,North China Craton

Tectonic stress fields are the key drivers of tectonic events and the evolution of regional structures.The tectonic stress field evolution of the Tanlu fault zone in Shandong Province,located in the east of the North China Craton(NCC),may have preserved records of the NCC’s tectonic history.Borehole television survey and hydraulic fracturing were conducted to analyze the paleo and present tectonic stress fields.Three groups of tensile fractures were identified via borehole television,their azimuths being NNW-SSE,NW-SE and NE-SW,representing multiple stages of tectonic events.Hydraulic fracturing data indicates that the study region is experiencing NEE-SWW-oriented compression and nearly-N-Soriented extension,in accordance with strike-slip and compression.Since the Cretaceous,the orientation of the extensional stress has evolved counterclockwise and sequentially from nearly-NW-SE-oriented to NE-SW-oriented and even nearly N-S-oriented,the stress state having transitioned from strike-slip-extension to strike-slip-compression,in association with the rotating and oblique subduction of the Pacific Plate beneath the NCC,with the participation of the Indian Plate.

COUPLED NUMERICAL SIMULATION ON COLD ROLLER'S TEMPERATURE FIFLD-PHASE TRANSFORMATION - STRESS FIELD DURING ITS QUENCHING PSOCESS

Complicated changns occur inside the steel parts during quenching process. The abruptly changed boundary conditions make the temperature field,micro - structure and stress field change dramatically in very short time, and these variables take a contact interactions in the whole process. In this paper, a three dimensional non - linear mathematical model for queeching process has been founded and the numerical simulation on temperature field,microstructre and stress field has been realized.In the FEM analysis, the incremental iteration method is used to deal with such complicated nonlinear as boundary nonlinear, physical property nonlinear,transformation nonlinear etc.The effect of stress on transformation kinetics has been considered in the calculation of microstructure. In the stress field anal- ysis,a thermo- elasto - plastic model has been founded, which considers such factors as transforma- tion strain,transformation plastic strain, themal strain and the effect of temperature and transforma- tion on mechanical propertier etc. The transient temperature field, microstructure distribution and stress field of the roller on any time can be displayed vividly,and the cooling curve and the changes of stress on any position can also be given.

Numerical Simulation of Temperature Field and Thermal Stress Field of Work Roll During Hot Strip Rolling

Based on the thermal conduction equations, the three-dimensional （3D） temperature field of a work roll was investigated using finite element method （FEM）. The variations in the surface temperature of the work roll during hot strip rolling were described, and the thermal stress field of the work roll was also analyzed. The results showed that the highest roll surface temperature is 593 ℃, and the difference between the minimum and maximum values of thermal stress of the work roll surface is 145.7 MPa. Furthermore, the results of this analysis indicate that temperature and thermal stress are useful parameters for the investigation of roll thermal fatigue and also for improving the quality of strip during rolling.

Simulation of Paleotectonic Stress Fields and Distribution Prediction of Tectonic Fractures at the Hudi Coal Mine, Qinshui Basin

Study on tectonic fractures based on the inversion of tectonic stress fields is an effective method. In this study, a geological model was set up based on geological data from the Hudi Coal Mine, Qinshui Basin, a mechanical model was established under the condition of rock mechanics and geostress, and the finite element method was used to simulate the paleotectonic stress field. Based on the Griffith and Mohr-Coulomb criterion, the distribution of tectonic fractures in the Shanxi Formation during the Indosinian, Yanshanian, and Himalayan period can be predicted with the index of comprehensive rupture rate. The results show that the acting force of the Pacific Plate and the India Plate to the North China Plate formed the direction of principal stress is N-S, NW - SE, and NE - SW, respectively, in different periods in the study area. Changes in the direction and strength of the acting force led to the regional gradients of tectonic stress magnitude, which resulted in an asymmetrical distribution state of the stress conditions in different periods. It is suggested that the low-stress areas are mainly located in the fault zones and extend along the direction of the fault zones. Furthermore, the high-stress areas are located in the junction of fold belts and the binding site of multiple folds. The development of tectonic fractures was affected by the distribution of stress intensity and the tectonic position of folds and faults, which resulted in some developed areas with level I and II. There are obvious differences in the development of tectonic fractures in the fold and fault zones and the anticline and syncline structure at the same fold zones. The tectonic fractures of the Shanxi Formation during the Himalayan period are more developed than those during the Indosinian and Yanshanian period due to the superposition of the late tectonic movement to the early tectonic movement and the differences in the magnitude and direction of stress intensity.